Mobile/fixed prosthetic knee systems

ABSTRACT

A prosthetic knee system includes a tibial tray, a non-rotating tibial insert, and a rotating tibial insert. The non-rotating tibial insert and the rotating tibial insert are selectively couplable to the tibial tray such that a fixed or a mobile orthopaedic prosthesis may be configured. In some embodiments, the tibial tray may be a fixed or mobile tibial tray. Additionally, in some embodiments, the prosthetic knee system may include a femoral component.

This patent application claims priority to and the benefit of U.S.Provisional Patent Application Ser. No. 60/829,432 entitled“Mobile/Fixed Prosthetic Knee Systems,” which was filed on Oct. 13, 2006by Luke J. Aram, et al. and to U.S. Provisional Patent Application Ser.No. 60/829,430 entitled “Mobile/Fixed Prosthetic Knee System,” which wasfiled on Oct. 13, 2006 by Stephen A. Hazebrouck, et al., the entirety ofeach of which is expressly incorporated herein by reference.

CROSS-REFERENCE TO RELATED U.S. PATENT APPLICATION

Cross-reference is made to U.S. Utility patent application Ser. No.11/859,442 entitled “Mobile/Fixed Prosthetic Knee Systems,” which wasfiled on Sep. 21, 2007 by Daniel D. Auger et al., to U.S. Utility patentapplication Ser. No. 11/859,451 entitled “Mobile/Fixed Prosthetic KneeSystems,” which was filed on Sep. 21, 2007 by Luke J. Aram et al., toU.S. Utility patent application Ser. No. 11/859,448 entitled“Mobile/Fixed Prosthetic Knee Systems,” which was filed on Sep. 21, 2007by Stephen A. Hazebrouck et al., and to U.S. Utility patent applicationSer. No. 11/859,425 entitled “Mobile/Fixed Prosthetic Knee Systems,”which was filed on Sep. 21, 2007 by John A. Bonitati et al., theentirety of each of which is expressly incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to an orthopaedic prosthesis,and more particularly to a knee prosthesis. Specifically, the presentdisclosure relates to the tibial and bearing components of a kneeprosthesis.

BACKGROUND

Movement (e.g., flexion and extension) of the natural human kneeinvolves movements of the femur and the tibia. Specifically, duringflexion and extension, the distal end of the femur and the proximal endof the tibia articulate relative to one another through a series ofcomplex movements. Damage (e.g., trauma) or disease can deteriorate thebones, articular cartilage, and ligaments of the knee, which canultimately affect the ability of the natural knee to function in such amanner. As a result, knee prostheses have been developed and implantedinto surgically prepared ends of the femur and tibia.

A typical knee prosthesis for a total knee replacement, for example,includes a tibial component or tibial tray coupled to the patient'stibia, a femoral component coupled to the patient's femur, and a bearingcomponent (or tibial insert) positioned between the tibial tray and thefemoral component and including a bearing surface to accommodate thecondyles of the femoral component. In some situations, it may bedesirable that the tibial insert rotate relative to the tibial tray.Such rotation more closely replicates the motion of the patient'snatural anatomy. In other cases, however, it may be desirable to preventthe tibial insert from rotating relative to the tibial tray. Forexample, various ligaments which support the knee may be compromised ordamaged. In such a case, rotation of the tibial insert relative to thetibial tray may create an unstable knee. As such, a surgeon will decideon a case-by-case basis whether to use a rotating or non-rotating tibialassembly. This decision may be made pre-operatively orintra-operatively, for example. Additionally, it may be desirable tochange a rotating tibial insert to a non-rotating tibial insert during arevision type surgery, for example.

SUMMARY

According to one aspect, an orthopaedic prosthesis assembly may includea tibial tray configured to be coupled to a surgically-prepared surfaceof the proximal end of a tibia and a tibial insert coupled to the tibialtray. The tibial tray may include a platform having an upper surface anda bottom surface. The tibial tray may also include a cavity having anopening defined in the upper surface of the platform. The cavity may bedefined by a sidewall.

The tibial insert may include a polymer bearing, a metal base, and ametal stem. The polymer bearing may include an upper bearing surfaceconfigured to contact a pair of femoral condyles and a bottom surface.The metal base may include an upper surface secured to the bottomsurface of the polymer bearing and a bottom surface in contact with theupper surface of the tibial tray. The metal stem may extend downwardlyfrom the bottom surface of the base. The metal stem may be received inthe cavity of the tibial tray. In some embodiments, the sidewalldefining the cavity and the metal stem may have corresponding taperssuch that the sidewall and the metal stem are in contact and form afriction lock therebetween. For example, the sidewall defining thecavity may have a Morse taper and the metal stem may have a Morse tapercorresponding to the Morse taper of the sidewall. Additionally, in someembodiments, the metal base includes a macro-texturized layer defined onthe upper surface. The polymer bearing may be compression molded to themetal base.

In some embodiments, the orthopaedic prosthesis may also include arotating tibial insert. The tibial insert may be removably coupled tothe tibial tray. The rotating tibial insert may be configured to becoupled to the tibial tray when the tibial insert is removed therefrom.The rotating tibial insert may be free to rotate about an axis relativeto the tibial tray when coupled thereto. The rotating tibial insert mayinclude a stem extending from a bottom surface. In such embodiments, thestem may be configured to be received in the cavity of the tibial traywhen the rotating tibial insert is coupled thereto.

According to another aspect, an orthopaedic prosthesis may include atibial tray, a tibial insert, and a screw. The tibial tray may beconfigured to be coupled to a surgically-prepared surface of theproximal end of a tibia. The tibial tray may include a platform havingan upper surface and a bottom surface. The tibial tray may also includea cavity defined by an inner sidewall and having an opening defined inthe upper surface of the platform.

The tibial insert may be coupled to the tibial tray and may include anupper bearing surface configured to contact a pair of femoral condyles.Additionally, the tibial insert may include a bottom surface in contactwith the upper surface of the tibial tray and a stem extendingdownwardly from the bottom surface and received in the cavity of thetibial tray. The stem may include a distal end having a threadedinternal passageway.

The screw may be positionable in the threaded internal passageway of thestem. The distal end of the stem may have a first width when the screwis positioned in the threaded internal passageway and may have a secondwidth when the screw is removed from the threaded internal passageway.The first width may be greater than the second width. Additionally, insome embodiments, the distal end of the stem may include a verticalslit, which is sized to allow the width of the distal end of the stem tobe increased. In some embodiments, the stem may include an outer wall.The outer wall may be forced against the inner sidewall of the tibialtray when the screw is positioned in the first position. Additionally,in some embodiments, the inner sidewall of the tibial tray may include aslot defined therein and the distal end of the stem may include an outerrim. In such embodiments, the outer rim may be received in the slot ofthe inner sidewall.

Accordingly to further aspect, an orthopaedic prosthesis may include atibial tray, a tibial insert, and a stem. The tibial tray may beconfigured to be coupled to a surgically-prepared surface of theproximal end of a tibia. The tibial tray may include a platform, a firsttrack, and a second track. The platform may have an upper surface and abottom surface. The first track may be defined in the upper surface ofthe platform. Similarly, the second track may be defined in the uppersurface of the platform. The tibial tray may also include a cavityhaving an opening defined the upper surface between the first track andthe second track.

The tibial insert may be coupled to the tibial tray. The tibial insertmay include an upper bearing surface, a bottom surface, and first andsecond rails. The upper bearing surface may be configured to contact apair of femoral condyles. The bottom surface may be in contact with theupper surface of the tibial tray. The first rail may extend downwardlyfrom the bottom surface and be received in the first track of the tibialtray. Similarly, the second rail may extend downwardly from the bottomsurface and be received in the second track. The tibial insert may alsoinclude a passageway defined therethrough. The passageway may include afirst opening defined in the upper bearing surface and a second openingdefined in the bottom surface. The tibial insert may be positionedrelative to the tibial tray such that the passageway is in registry withthe opening of the cavity of the tibial tray.

The stem may be coupled to the tibial insert and the tibial tray. Forexample, the stem may be received in the passageway of the tibial insertand extend through aperture of the tibial tray. In some embodiments,each of the first track, the second track, the first rail, and thesecond rail may have a substantially dovetail cross-section, asubstantially rectangular cross-section, and/or a substantially T-shapedcross-section. Additionally, the first track and the first rail may havecorrespondingly shaped cross-sections. The second track and the secondrail have correspondingly shaped cross-sections that are different fromthe cross-sections of the first track and the first rail.

In some embodiments, the stem may include an internal passageway. Thetibial tray may include an aperture defined at a distal end of thecavity. In such embodiments, the orthopaedic prosthesis assembly mayfurther include a fastener received in the passageway of the stem andthe threaded aperture of the tibial tray to secure the tibial insert tothe tibial tray in a fixed position. Further, in some embodiments, theorthopaedic prosthesis assembly may include a rotating tibial insert. Insuch embodiments, the rotating tibial insert may be configured to becoupled to the tibial tray when the tibial insert is removed therefrom.The rotating tibial insert may be free to rotate about an axis relativeto the tibial tray.

According to yet another aspect, an orthopaedic prosthesis may include atibial tray, a tibial insert, and a metal rim. The tibial tray may beconfigured to be coupled to a surgically-prepared surface of theproximal end of a tibia. The tibial tray may include a platform. Theplatform may have an upper surface, a bottom surface, and a side surfaceextending between the upper surface and the bottom surface. The sidesurface may have a taper.

The tibial insert may be coupled to the tibial tray. The tibial insertmay include an upper bearing surface, a bottom surface, and a sidesurface extending between the upper bearing surface and the bottomsurface. The upper bearing surface may be configured to contact a pairof femoral condyles. The bottom surface may be in contact with the uppersurface of the tibial tray.

The metal rim may be secured to the side surface of the tibial insertand may extend downwardly with respect to the bottom surface of thetibial insert. The metal rim may have a taper corresponding to the taperof the side surface of the tibial tray such that the metal rim and sidesurface of the tibial tray are in contact and form a friction locktherebetween. For example, the side surface of the tibial insert mayinclude a Morse taper and the metal rim may include a Morse tapercorresponding to the Morse taper of the side surface of the tibialinsert.

In some embodiments, the tibial tray may include a cavity defined in theplatform. The cavity may be defined by a sidewall. Additionally, thetibial insert may include a stem extending downwardly from the bottomsurface and being received in the cavity of the tibial tray. In suchembodiments, the orthopaedic prosthesis assembly may further include ametal ring secured to the stem. The sidewall defining the cavity and themetal ring may include corresponding tapers such that the sidewall andthe metal ring are in contact and form a friction lock therebetween.Further, in some embodiments, the tibial insert may include a passagewayhaving an opening defined in the upper surface and extending through thestem. Similarly, the tibial tray may include a threaded aperture definedat a distal end of the cavity. In such embodiments, the orthopaedicprosthesis assembly may further include a fastener received in thepassageway of the tibial insert and the threaded aperture of the tibialtray to secure the tibial insert to the tibial tray. The tibial tray mayalso include a slot defined in the side surface. The slot may define aclosed path. The tibial insert may include a tab extending from an innersurface of the metal rim. The tab may also define a closed path and bereceived in the slot of the tibial tray.

According to yet a further aspect, an orthopaedic prosthesis may includea tibial tray, a tibial insert, and a metal ring. The tibial tray may beconfigured to be coupled to a surgically-prepared surface of theproximal end of a tibia. The tibial insert coupled to the tibial trayand the metal ring secured to the side surface of the tibial insert. Thetibial tray may be include a platform having an upper surface and abottom surface and a rim extending upwardly from the upper surface ofthe platform. The rim may define a closed path and may have a taper.

The tibial insert may include an upper bearing surface, a substantiallyplanar bottom surface, and a side surface extending between the upperbearing surface and the bottom surface. The upper bearing surface may beconfigured to contact a pair of femoral condyles. The substantiallyplanar bottom surface may be in contact with the upper surface of theplatform of the tibial tray.

The metal ring may include a bottom surface substantially co-planar withthe bottom surface of the tibial insert. The metal ring may have a tapercorresponding to the taper of the rim of the tibial tray such that themetal ring and the rim of the tibial tray are in contact and form afriction lock therebetween. For example, the sidewall of the tibialinsert may have a Morse taper and the metal ring may have a Morse tapercorresponding to the Morse taper of the rim of the tibial insert.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the following figures,in which:

FIG. 1 is a perspective view of a tibial tray including generally“C-shaped” cutout recesses;

FIG. 2 is a top view of the tibial tray of FIG. 1;

FIG. 3 is a bottom perspective view of a non-rotating or fixed tibialinsert for use with the tibial tray of FIGS. 1 and 2;

FIG. 4 is a bottom perspective view of a rotating tibial insert for usewith the tibial tray of FIGS. 1 and 2;

FIG. 5 is a side view of a tibial insert having removable tabs;

FIG. 6 is a top view of a tibial tray configured to be coupled with thetibial insert of FIG. 5;

FIG. 7 is a perspective view of a fixed tibial assembly including atibial tray, a tibial insert, and a locking rail system fixed to thetibial insert;

FIG. 8 is a perspective view of a fixed tibial assembly including atibial tray, a tibial insert, and a locking rail system fixed to thetibial tray;

FIG. 9 is a perspective view of a tibial assembly including a tibialtray, a tibial insert, and a removable locking rail system to convertthe tibial insert from a rotating tibial insert to a fixed tibialinsert;

FIG. 10 is a part-side, part-sectional view of a tibial tray and anon-rotating tibial insert configured to be coupled with the tibialtray;

FIG. 11 is a top view of the tibial tray and the tibial insert of FIG.10;

FIG. 12 a side view of the tibial tray of FIGS. 10 and 11 and a rotatingtibial insert configured to be coupled with the tibial tray;

FIG. 13 is a top view of the tibial tray and the tibial insert of FIG.12;

FIG. 14 is a sectional view of a prosthetic knee system including atibial tray, a tibial spacer, and a tibial insert;

FIG. 15 is a sectional view of a tibial tray and a non-rotating tibialinsert including a metal base having a tapered stem configured to becoupled with the tibial tray;

FIG. 16 is a sectional view of a modular tibial tray for use with anon-rotating tibial insert;

FIG. 17 is a sectional view of another modular tibial tray for use witha rotating tibial insert;

FIG. 18 is a sectional view of a tibial tray and a tibial insertconfigured to be coupled to the tray;

FIG. 19 a bottom view of the rotating tibial insert of FIG. 18 includingtwo curved rails;

FIG. 20 is a bottom view of an alternative tibial insert for use withthe tibial tray of FIG. 18 including a rail extending around a perimeterof the platform of the tibial insert;

FIG. 21 is a top view of the tibial tray of FIG. 18 including two guidetracks formed therein;

FIG. 22 a is a perspective view of a tibial tray, a tibial insertconfigured to be coupled with the tibial tray, and four threaded postsconfigured to be coupled to the tibial tray and the tibial insert whenthe tibial insert is to be used as non-rotating tibial insert;

FIG. 22 b is a top view of the tibial tray of FIG. 22 a showing analternative configuration for a plurality of threaded bores of thetibial tray;

FIG. 23 is a sectional view of the tibial tray, tibial insert, and theposts of FIG. 22 a;

FIG. 24 is a part-side, part-sectional view of a rotating tibialassembly including a rotating tibial insert, a tibial tray, and a ring;

FIG. 25 is an exploded, part-side, part-sectional view of a non-rotatingtibial assembly including a non-rotating tibial insert, a tibial tray,and a ring;

FIG. 26 is an assembled, sectional view of the tibial system of FIG. 25;

FIG. 27 is an exploded, sectional view of another prosthetic knee systemincluding a tibial tray, a tibial insert, and a fastener;

FIG. 28 is an assembled, sectional view of the prosthetic knee system ofFIG. 27;

FIG. 29 is a side view of a portion of the stem of the tibial tray ofthe prosthetic knee system of FIGS. 27-28;

FIG. 30 is a part-sectional, part-side view of a tibial insert includinga platform and a stem removably coupled to the platform;

FIG. 31 is a bottom, sectional view taken along line 31-31 of the tibialinsert of FIG. 30 showing a track formed in the platform to permitanterior/posterior glide of the platform relative to the stem;

FIG. 32 is a side view with portions broken away of the tibial insert ofFIGS. 30 and 31;

FIG. 33 is a side view of an alternative stem for use with the tibialinsert of FIGS. 30-32;

FIG. 34 a is a top view of a orthopaedic prosthesis assembly including atibial tray having two peripheral rails and a fixed tibial insertretained in a fixed position relative to the tibial tray;

FIG. 34 b is a top view of a rotating tibial assembly including thetibial tray shown in FIG. 34 a and a rotating tibial insert free torotate relative to the tibial tray;

FIG. 35 is a sectional view of the tibial tray and the fixed tibialinsert of FIG. 34 a showing the tibial insert received within the railsof the tibial tray;

FIG. 36 is a sectional view of a modular tibial tray including aplatform component and a mobile stem component;

FIG. 37 is a sectional view of a fixed stem component able to be coupledto the platform component shown in FIG. 36;

FIG. 38 is a side view of the fixed stem component of FIG. 37 and afixed tibial insert (shown in section) configured to be coupled to thefixed stem component;

FIG. 39 is a bottom view of the fixed stem component of FIGS. 37 and 38;

FIG. 40 is a sectional view of a revision stem component configured tobe coupled to the platform component shown in FIG. 36;

FIG. 41 is a part-sectional view of a prosthetic knee system including atibial insert, a tibial tray, and a plurality of locking posts;

FIG. 42 is a top view of the tibial tray of FIG. 41 includingthrough-holes for receiving the locking posts to fix the tibial bearingrelative to the tibial tray;

FIG. 43 is a bottom view of a platform component of a modular tibialinsert including an opening and a guide track formed in a bottom surfaceof the platform component;

FIG. 44 is a sectional view taken along line 44-44 of the platformcomponent of FIG. 43;

FIG. 45 is a side view of a stem component configured to be coupled tothe platform component of FIGS. 43 and 44 in order to form a modulartibial insert;

FIG. 46 is a front view of the stem component of FIG. 45;

FIG. 47 is a sectional view of a tibial tray including a threaded colletwithin a distal portion of the stem of the tibial tray;

FIG. 48 is an end view of the threaded collet of FIG. 47;

FIG. 49 is a sectional view of a tibial tray and a tibial insert coupledto the tray showing the tibial insert including an upper, polymer and alower, metal base configured to be coupled to the metal tibial tray;

FIG. 50 is a top view of the tibial tray of FIG. 49 including a bearingsystem;

FIG. 51 a is a side view of a tibial insert including a stem havingflanges or pegs coupled thereto;

FIG. 51 b is a side view of a tibial insert including a stem havingflexible tabs coupled thereto;

FIG. 52 is a bottom view of a platform component of a modular tibialtray including a pair of generally “C-shaped” guide tracks;

FIG. 53 is a sectional view taken along lines 53-53 of the platformcomponent of FIG. 52;

FIG. 54 is a side view of a stem component of the modular tibial trayincluding a threaded shaft and a locking bolt configured to be receivedwithin either one of the guide tracks of the platform component shown inFIGS. 52 and 53;

FIG. 55 is a top view of a tibial assembly including a tibial insert, atibial tray, and a pair of metal clamps configured to be coupled to thetibial insert and the tibial tray in order to prevent relative movementbetween the tibial insert and the tibial tray;

FIG. 56 is a sectional view taken along line 56-56 of a portion of thetibial assembly of FIG. 55 showing one of the metal clamps including atab to be received within a peripheral groove of the tibial insert and ascrew to be received within the tibial tray in order to couple the clampto the tibial insert and the tibial tray and prevent relative movementtherebetween;

FIG. 57 is a top view of a tibial assembly similar to the tibialassembly shown in FIGS. 55 and 56 including five separate metal clampsconfigured to be coupled to the tibial insert and the tibial tray of thetibial assembly in order to prevent relative movement between the tibialinsert and the tibial tray;

FIG. 58 is a sectional view taken along line 58-58 of a portion of thetibial assembly of FIG. 57;

FIG. 59 is a top view of a spring-loaded clamp assembly configured to becoupled to a tibial insert and a tibial tray in order to preventrelative movement between the tibial bearing and the tibial tray;

FIG. 60 is a sectional, exploded view of a fixed tibial assemblyincluding a tibial insert and a modular tibial tray including anextendable stem component;

FIG. 61 is a sectional view of a modular tibial tray configured for usewith the tibial insert of FIG. 60 in order to provide a rotating tibialassembly;

FIG. 62 is a perspective view of another tibial tray;

FIG. 63 is a sectional view taken along line 63-63 of FIG. 62;

FIG. 64 is a perspective view of another tibial insert configured to beused with the tibial tray of FIG. 62;

FIG. 65 is a side view of the tibial insert of FIG. 64 coupled to thetibial tray of FIGS. 62 and 63;

FIG. 66 is a sectional view taken along line 66-66 of FIG. 65;

FIG. 67 is a perspective view of another tibial tray similar to thetibial tray shown in FIG. 62;

FIG. 68 is a perspective view of another tibial insert similar to thetibial insert shown in FIG. 64;

FIG. 69 is a perspective view of another tibial tray;

FIG. 70 is a perspective view of another tibial insert configured to beused with the tibial tray of FIG. 69;

FIG. 71 is a perspective view of a prosthetic knee assembly including atibial insert, a tibial tray, and a locking pin;

FIG. 72 is a side view of the prosthetic knee assembly of FIG. 71;

FIG. 73 is a perspective view of another prosthetic knee assemblyincluding a tibial insert, a tibial tray, and a locking insert;

FIG. 74 is a side view of the prosthetic knee assembly of FIG. 73;

FIG. 75 is a top view of another tibial tray showing an irregularlyshaped cutout formed in the platform around the bore of the tibial tray;

FIG. 76 is a top view of another tibial tray showing arectangular-shaped cutout formed in the platform around the bore of thetibial tray;

FIG. 77 is a top view of another tibial tray showing a plurality ofcutout portions each configured to receive a mating tab from acorresponding tibial insert (not shown);

FIG. 78 is a top view of another tibial tray showing a plurality ofelongated openings;

FIG. 79 is a top view of yet another tibial tray showing a plurality ofinterconnected openings;

FIG. 80 is a top view of another tibial tray showing a plurality ofcurved openings;

FIG. 81 is an enlarged sectional view of an exemplary cross-sectionalshape of any of the openings of FIGS. 77-80;

FIG. 82 is an enlarged sectional view of an exemplary cross-sectionalshape of any of the openings of FIGS. 77-80;

FIG. 83 is an enlarged sectional view of an exemplary cross-sectionalshape of any of the openings of FIGS. 77-80;

FIG. 84 is a front view of a fixed tibial assembly including a tibialtray, a tibial insert, and a locking pin;

FIG. 85 is a sectional view of the fixed tibial assembly shown in FIG.84;

FIG. 86 is a perspective view of a rotating tibial assembly including atrack system to guide the rotating movement of the tibial insertrelative to the tibial tray;

FIG. 87 is a perspective view of a tibial system including a tibial trayhaving a recessed track formed therein, a rotating tibial insert, and afixed tibial insert having a rail to be received within the recessedtrack of the tray;

FIG. 88 is a perspective view of the prosthetic knee system shown inFIGS. 41 and 42 showing alternative locking pins for insertion into thetray, the insert, and/or the tibia to prevent movement of the insertrelative to the tray.

FIG. 89 is a perspective view of another embodiment of a tibial tray;

FIG. 90 is a perspective view of a non-rotating tibial insert for usewith the tibial tray of FIG. 89;

FIG. 91 is a perspective view of a rotating tibial insert for use withthe tibial tray of FIG. 89;

FIG. 92 is an exploded perspective view of another embodiment of anorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 93 is a perspective view of the orthopaedic prosthesis assembly ofFIG. 92 shown in an assembled configuration;

FIG. 94 is an exploded perspective view of the orthopaedic prosthesisassembly of FIG. 92 including a rotating tibial insert;

FIG. 95 is a perspective view of the orthopaedic prosthesis assembly ofFIG. 94 shown in an assembled configuration;

FIG. 96 is an exploded perspective view of another embodiment of anorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 97 is an exploded perspective view of another embodiment of anorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 98 is a cross-sectional view of the orthopaedic prosthesis assemblyof FIG. 97 taken generally along the line 97-97;

FIG. 99 is a cross-sectional view of the orthopaedic prosthesis assemblyof FIG. 97 in an assembled configuration;

FIG. 100 is an exploded perspective view of another embodiment of anorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 101 is an exploded perspective view of another embodiment of theorthopaedic prosthesis assembly of FIG. 100;

FIG. 102 is an exploded perspective view of the orthopaedic prosthesisassembly of FIG. 100 including a rotating tibial insert;

FIG. 103 is an exploded perspective view of another embodiment of anorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 104 is an exploded perspective view of another embodiment of theorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 105 is an exploded perspective view of another embodiment of anorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 106 is an exploded perspective view of another embodiment of theorthopaedic prosthesis assembly of FIG. 105;

FIG. 107 is an exploded perspective view of another embodiment of anorthopaedic prosthesis assembly including a non-rotating tibial insert;

FIG. 108 is a bottom perspective view of an orthopaedic prosthesisassembly including a tibial tray and an adjustable stem;

FIG. 109 is a bottom perspective view of another embodiment of theorthopaedic prosthesis assembly of FIG. 108;

FIG. 110 is a top perspective view of the orthopaedic prosthesisassembly of FIG. 109;

FIG. 111 is a bottom plan view of another embodiment of the orthopaedicprosthesis assembly of FIG. 109;

FIG. 112 is a top plan view of one embodiment of a tibial tray;

FIG. 113 is a top plan view of another embodiment of the tibial tray ofFIG. 112;

FIG. 114 is a cross-sectional view of the tibial tray of FIG. 112 takenalong the line 114-114 and including a stem secured thereto;

FIG. 115 is an enlarged sectional view of one embodiment of the tibialtray of the FIG. 112;

FIG. 116 is an enlarged section view of another embodiment of the tibialtray of FIG. 112;

FIG. 117 is an enlarged section view of another embodiment of the tibialtray of FIG. 112;

FIG. 118 is an exploded bottom perspective view of another embodiment ofthe orthopaedic prosthesis assembly of FIG. 109;

FIG. 119 is a top plan view of a stem of the orthopaedic prosthesisassembly of FIG. 118;

FIG. 120 is a top perspective view of the stem of FIG. 119;

FIG. 121 is a bottom perspective view of another embodiment of anorthopaedic prosthesis assembly; and

FIG. 122 is front elevation view of the orthopaedic prosthesis assemblyof FIG. 121.

DETAILED DESCRIPTION OF THE DRAWINGS

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific exemplary embodimentsthereof have been shown by way of example in the drawings and willherein be described in detail. It should be understood, however, thatthere is no intent to limit the disclosure to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the invention as defined by the appended claims.

Various prosthetic knee systems are described within the presentdisclosure. Such prosthetic knee systems may include one or more tibialtrays, one or more tibial inserts, and/or one or more locking mechanismsor other components associated with the aforementioned tray(s) andinsert(s). A first combination of these components of the prostheticknee systems disclosed herein provides a rotating tibial assemblywhereby the tibial insert is able to rotate about a longitudinal axisrelative to the tibial tray. A second combination of the components ofthe prosthetic knee systems disclosed herein provides a non-rotating orfixed knee assembly whereby the tibial insert is fixed relative to thetibial tray and is not able to rotate about the longitudinal axis. Assuch, many of the knee prosthetic systems disclosed herein includecomponents which may be arranged to provide for both a rotating kneeassembly and a non-rotating knee assembly.

Looking now to FIGS. 1-4, a prosthetic knee system includes a tibialtray 12 (shown in FIGS. 1 and 2), a fixed tibial insert 14 (shown inFIG. 3), and a rotating tibial insert 16 (shown in FIG. 4). As isdiscussed in greater detail below, the fixed tibial insert 14 may becombined with the tibial tray 12 to provide a fixed or non-rotatingtibial assembly while the rotating tibial insert 16 may be combined withthe tibial tray 12 to provide a rotating or mobile knee assembly. Inother words, a single tray (i.e., the tibial tray 12) may be used witheither the fixed tibial insert 14 or the mobile tibial insert 16. Such asystem allows the surgeon to implant the tibial tray 12 within apatient's tibia and then ascertain whether the fixed or mobile tibialinsert 14, 16 would be more appropriate for the particular kneereplacement at hand. Further, a prosthetic knee system having a singletray for use with both mobile and fixed inserts allows the surgeon toperform a revision surgery to be performed without having to remove thetibial tray from the patient's tibia. In other words, if original totalknee arthroplasty (TKA) was performed to implant the rotating insert 16shown in FIG. 4, a revision surgery to replace the rotating insert 16with the fixed insert 14 may not require the surgeon to remove thetibial tray 12. Accordingly, such a revision surgery may be lessinvasive to the patient than a revision surgery requiring the tibialtray to be removed.

Looking now to FIGS. 1 and 2, the tibial tray 12 includes a platform 20and a stem 22 coupled to a bottom surface 24 of the platform 20.Illustratively, a top surface 26 of the platform 20 is generally planarand, in some embodiments, may be highly polished. A cavity or bore 30through the platform 20 and into the stem 22 is formed to receive acomplimentary stem of a tibial insert, as is discussed below. Theplatform 20 of the tibial tray 12 includes two protrusions 32 extendinginwardly from a sidewall defining the bore 30 formed through theplatform 20. Illustratively, the protrusions 32 extend toward each otherfrom across opposite sides of the open end or aperture of the bore 30.

The platform 20 also includes two C-shaped guide tracks 34 which arerecessed from top surface 26 of the platform 20. Illustratively, theguide tracks 34 extend between the protrusions 32 as shown best in FIG.2. Additionally, the platform 20 includes two recesses defined in thesidewall defining the bore 30. Each recess has a substantially “C” shapeand is in communication with each corresponding guide track 34 as shownin FIG. 1 and in phantom in FIG. 2.

Looking now to FIG. 3, the fixed or non-rotating insert 14 includes aplatform 40 having an upper bearing surface (not shown) configured tomate with the articulating surface of the condyles of a coordinatingfemoral component (not shown). The fixed insert 14 further includes aconnector hub 42 coupled to a bottom surface 44 of the of the platform40. The connector hub 42 is generally circular in shape and includes twonotches 46 formed therein. The notches 46 are illustratively positionedacross from each other and are formed to receive the protrusions 32 ofthe tibial tray 12, as is discussed in greater detail below. Theconnector hub 42 further includes two flexible locking tabs 48 which maybe moved from their normal, extended position to a inward or retractedposition.

The rotating insert 16, shown in FIG. 4, includes a platform 50 having atop, bearing surface (not shown) and a stem 52 coupled to a bottomsurface 54 of the platform 50. The rotating insert 16 further includestwo flanges or rotational guides 56 coupled to the stem 52 and thebottom surface 54 of the platform 50. Illustratively, the guides 56 arecurved and are positioned on opposite sides of the stem 52 from eachother.

In use, the surgeon may implant the tibial tray 12 within the patient'stibia and may then make a determination as to whether the non-rotatinginsert 14 or the rotating insert 16 should be used for the particularTKA being performed. In situations where the non-rotating insert 14 isdesired, the connector hub 42 is received within the bore 30 of thetibial tray 12 such that the bottom surface 44 of the non-rotatinginsert 14 is adjacent to and in contact with the top surface 26 of thetibial tray 12. The protrusions 32 of the tibial tray 12 are receivedwithin the notches 46 of the non-rotating insert 14 in order to preventrotational motion of the non-rotating insert 14 relative to the tibialtray 12. The locking tabs 48 of the fixed insert 14 are received withinthe recesses 36 of the tibial tray 12 in order to further preventrelative movement between the bearing 14 and the tray 12. The lockingtabs 48 also aide in preventing “lift-off” or axial motion of the insert14 in a direction away from the tray 12. Illustratively, the tibial tray12 and the fixed bearing 14 cooperate to provide a fixed tibialassembly.

In situations where the mobile or rotating insert 16 is desired, therotational guides 56 of the bearing 16 are received on the respectiveguide tracks 34 of the tibial tray 12 while the stem 52 of the insert 16is received within the bore 30 of the tray 12. The insert 16 is able torotate about a longitudinal axis running through the center of the stems22, 52 of each component. The protrusions 32 of the tibial tray 12operate as rotational stops to limit the rotational movement of therotating insert 16 relative to the tibial tray 12. For example, as therotating insert 16 rotates either clockwise or counterclockwise, therotational guides 56 of the insert 16 will engage the protrusions 32 ofthe tibial tray 12 to prevent further movement in that particulardirection. Illustratively, the arc length of each rotational guide 56 isgenerally smaller than the arc length of the guide track 34 within whicheach guide 56 is positioned. The arc length of the rotational guides 56may be adjusted to increase or decrease the amount of rotationalmovement of the insert 16 relative to the tray 12. For example, in oneparticular embodiment, the arc length of the rotational guides 56 isabout 10 degrees to about 40 degrees. Illustratively, the tibial tray 12and the rotating insert 16 cooperate to provide a rotating tibialassembly.

Looking now to FIGS. 5 and 6, a tibial tray 112, as shown in FIG. 6, anda tibial insert 114, as shown in FIG. 5, cooperate to provide aprosthetic knee system which may be arranged to provide a rotatingtibial assembly and a fixed or non-rotating tibial assembly, as isdiscussed in greater detail below. The tibial insert 114 includes aplatform 140 having an upper bearing surface 141 and a stem 142 coupledto a bottom surface 144 of the platform 140. The tibial insert 114further includes first and second removable tabs 150 which may becoupled to the bottom surface 144 of the platform 140 or which may beremoved from the bottom surface 144 of the platform 140. The tabs 150may be snapped, screwed, press-fit or otherwise coupled to the bottomsurface 144 such that the tabs 150 may also be generally easily removedfrom the platform 140 as desired.

The tibial tray 112, shown in FIG. 6, includes a platform 120, a stem122, and a bore 130 formed through the platform 120 and into the stem122. Illustratively, a pair of slots 160 are formed in a top surface 126of the platform 120. The slots 160 correspond in size, shape, andlocation to the removable tabs 150 of the tibial insert 114. As such,the tibial insert 114 may be used as a fixed tibial insert when the tabs150 are coupled to the platform 120 of the tibial insert 114. In such aconfiguration, the tabs 150 are each received within a respective one ofthe slots 160 of the tibial tray 112 in order to prevent rotation of thetibial insert 114 relative to the tray 112.

However, the tibial insert 114 may also be used as a rotating tibialinsert when the tabs 150 are removed from the platform 140 of the tibialinsert 114. In this configuration, the tibial insert 114 is able torotate freely relative to the tibial tray 112 about a longitudinal axisthrough the stem 122 of the tibial tray 112. Accordingly, the tibialtray 112 and the tibial insert 114 shown in FIGS. 5 and 6 may beconfigured to provide either a rotating tibial assembly or a fixedbearing assembly, as desired. Further, illustratively, the prostheticknee system shown in FIGS. 5 and 6 includes only a single tibial tray(i.e., the tibial tray 110) and a single tibial insert (i.e., the tibialinsert 112) having a component (i.e., the tabs 130) which may beselectively used to provide either the fixed or mobile bearingassemblies. While the prosthetic knee system of FIGS. 5 and 6 is shownto include tabs removably coupled to the bottom surface of a tibialinsert with corresponding slots formed in the top surface of the tibialtray, it is within the scope of this disclosure to include a prostheticknee system whereby the tabs are removably coupled to the top surface ofthe tibial tray and the bottom surface of the tibial insert includesslots formed to receive the tabs therein.

For example, FIGS. 7-9 show various prosthetic knee systems having fixedas well as removable tabs or rail systems. Looking first to FIG. 7, atibial tray 212 and a tibial insert 214 cooperate to provide a fixedtibial assembly. The tibial insert 214 includes a platform 240 having anupper bearing surface 241 and a stem 242 coupled to a bottom surface 244of the platform 240. The tibial insert 214 further includes first andsecond keys or tabs 250 coupled to the bottom surface 244 of theplatform 240. Illustratively, the tabs 250 are generally rectangular inshape and include outwardly-extending flanges 252. The tabs 250 may bemade from a polymer and molded with the platform 240 or attached lateronce the platform 240 has been molded. Alternatively, the tabs 250 maybe made of metal and may be compression molded into the polymer platform240. While the tibial insert 214 includes two fixed tabs 250, it iswithin the scope of this disclosure to provide any number of fixed railsextending downwardly from any location on the bottom surface 244 of theplatform 240 of the tibial insert 214.

The tibial tray 212 includes a platform 220, a stem 222, and a bore 230formed though the platform 220 and into the stem 222. The tibial tray212 further includes a pair of slots or tracks 260 formed in a topsurface 226 of the platform 220. The slots 260 correspond in size andlocation to the fixed tabs 250 of the tibial insert 214 are generallyelongated and rectangular in shape. However, the slots 260 may be formedto include a cut-out portions (not shown) corresponding to theoutwardly-extending flanges 252 of the tabs 250. Illustratively, theslots 260 are defined by curved or rounded outer edges 261. During use,the tabs 250, fixed to the bottom surface 244 of the insert 214, areeach received within a respective one of the slots 260 of the tibialtray 212 in order to prevent rotation of the tibial insert 214 relativeto the tray 212. The outwardly-extending flanges 252 of the tabs 250operate to prevent lift-off of the insert 214 away from the tray 212. Inorder to provide a rotating tibial assembly, a rotating tibial insert(not shown) without keys 250 may be provided for use with the tray 212.

Looking now to FIG. 8, a prosthetic knee system similar to that shown inFIG. 7 is provided. As such, like reference numbers have been used todenote like features. Illustratively, the tibial tray 212 of FIG. 8includes a pair of slots or tracks 260 formed in the bottom surface 244of the platform 240 to receive a corresponding pair of tabs or keys 250fixed to and extending upwardly from the tip surface 226 of the platform220 of the tibial tray 212. The tabs 250 coupled to the platform 220 maybe metal and may be formed integrally with the platform 220 or may beattached to the platform 220 at a later time. During use, the tabs 250fixed to the top surface 226 of the tray 212 are each received within arespective one of the slots 260 of the tibial insert 214 in order toprevent rotation of the tibial insert 214 relative to the tray 212. Asshown in FIGS. 7 and 8, the locking tabs 250 may be coupled to eitherthe tray 212 or the insert 214 while the corresponding slots 260 may beformed in the other of the tray 212 or the insert 214. A separate tray(not shown) without the keys 250 may be provided for use with the insert212 shown in FIG. 8 in order to provide a rotating knee assembly.

Looking now to FIG. 9, a prosthetic knee system similar to that shown inFIGS. 4 and 5 and showing removable tabs or rails 270 is provided inorder to convert the knee system from a rotating tibial assembly to afixed tibial assembly, as is discussed below. Illustratively, a tibialinsert 272 includes a platform 274 having an upper bearing surface (notshown) and a stem 276 coupled to a bottom surface 278. A pair of slotsor tracks 280 are formed in the bottom surface 278 of the platform 274.Illustratively each slot 280 is elongated and generally rectangular inshape. A tibial tray 282 of the system includes a platform 284, a stem286, and a cavity or bore 288 formed through the platform 284 and intothe stem 286 to receive the stem 276 of the insert 272 therein.Illustratively, a pair of slots or tracks 290 are formed in a topsurface 292 of the platform 284. The slots 290 of the tray 282correspond in size, shape, and location to the slots 280 of the insert272. The knee system further includes a pair of locking tabs 270 whichmay each be inserted into one of the slots 280 of the insert 272 and acorresponding slot 290 of the tray 282 in order to prevent rotation ofthe tibial insert 272 relative to the tray 282. Each locking tab 270includes upper and lower outwardly-extending flanges 293 to be snappedor press-fit into a respective slot 280 or 290 of the correspondinginsert 272 and tray 282. Illustratively, the locking tabs 270 may bemade from metal or a polymer. Accordingly, the tibial insert 272 may beused as a fixed tibial insert when the locking keys 270 are insertedinto the slots 280, 290 of the tibial insert 272 and the tibial tray 282and may also be used as a rotating tibial insert when the locking rails270 are removed.

It should be appreciated that in some embodiments, the tab-and-slotconfiguration of the embodiments of FIGS. 5-9 may be incorporated withthe embodiment of FIGS. 1-4 to provide a more rigid coupling of thetibial insert 14 to the tibial tray 12. For example, one or more of thetabs 150, 250, 270 may be coupled to or integral with the bottom surface44 of the tibial insert 14 and received in one or more slots defined inthe top surface 26 of the tibial tray 12.

Looking now to FIGS. 10-13, yet another prosthetic knee system includingnon-rotating and rotating tibial assemblies is provided. The prostheticknee system includes a tibial tray 312, a fixed or non-rotating tibialinsert 314 (shown in FIGS. 10 and 11), and a rotating tibial insert 316(shown in FIGS. 12 and 13). Illustratively, the tibial tray 312 and thenon-rotating insert 314 cooperate to provide a fixed tibial assemblywhile the tibial tray 312 and the rotating insert 316 cooperate toprovide a rotating tibial assembly.

The tibial tray 312 includes a platform 320 and a stem 322 coupled tothe bottom surface 324 of the platform 320. The platform 320 includes acenter stepped section to define an upper platform 340 and a lowerplatform 342. The lower platform 342 is larger than the upper platform340 to define an outer ledge 344 of the platform 320.

Looking now to FIGS. 10 and 11, the fixed tibial insert 314 includes anupper bearing surface 315, a bottom surface 346, and a recess or cavity348 formed in the bottom surface 346 and sized to receive the upperplatform 340 of the tibial tray 312 therein. In such a position, thebottom surface 346 of the tibial insert 314 is configured to engage theledge 344 of the lower platform 342 of the tray 312. As such, when theupper platform 340 of the tibial tray 312 is received within the recess348 of the non-rotating tibial insert 314, the insert 314 is preventedfrom rotating relative to the tray 312. As shown in FIGS. 10 and 11, thetibial insert 314 is sized such that an outer perimeter of the lowerplatform 342 of the tibial tray 312 is generally the same size as anouter perimeter of the tibial insert 314. However, in some embodiments,the outer perimeter of the lower platform 342 of the tibial tray 312 maybe slightly larger than the size of the outer perimeter of the tibialinsert 314 to provide greater surface area for supporting the tibialinsert 314 such that the tibial tray 312 can accommodate tibial insertsof varying sizes.

Looking now to FIGS. 12 and 13, the rotating tibial insert 316 includesa platform 370 and a stem 372 coupled to the bottom surface 374 of theplatform 370 and configured to be received within a bore 330 of thetibial tray 312. Illustratively, the rotating tibial insert 316 is sizedsuch that an outer perimeter of the bottom surface 374 of the platform370 is generally the same size as the outer perimeter of upper platform340 of the tibial tray 312 and is configured to rest on an upper surface376 of the upper platform 340 of the tray 312 for rotation relative tothe tray 312. A metal ring 375 may be provided for use with the rotatingtibial insert 316. Illustratively, the metal ring 375 may be configuredfor placement around the upper platform 340 of the tibial tray 312 inorder to surround the upper platform 340 in order to further support anyunsupported portions of the polymer platform 370 of the rotating tibialinsert 316 to prevent any possible cold flow of the polymer platform 370during use. Illustratively, the metal ring 375 may be rigidly fixed tothe tibial tray 312 to prevent any metal-on-metal movement between thering 375 and the tray 312. As such, the metal ring 375 may includeflexible tabs (not shown) configured to be received within undercutportions of the upper and/or lower platform portions 340, 342 of thetibial tray 312.

Looking now to FIG. 14, another prosthetic knee system is provided whichincludes a tibial tray 412, a tibial insert 414, and a spacer 413.Illustratively, the tray 412 and the tibial insert 414 cooperate toprovide a non-rotating tibial assembly while the tray 412, the spacer413, and the insert 414 cooperate to provide a rotating tibial assembly.The tibial tray 412 includes a platform 420 and a stem 422 coupled to abottom surface 424 of the platform 420. A bore 430 of the tray 412 isformed through the platform 420 and into the stem 422. The platform 420of the tray 412 includes an outer rim 440 extending upwardly from anupper surface 442 of the platform 420. The outer rim 440 extends aroundthe periphery of the platform 420 and cooperates with the upper surface442 of the platform 420 to define a cavity 444 therein.

In a first or fixed configuration, a stem 450 of the tibial insert 414is received within the bore 430 of the tibial tray 412 such that abottom surface 452 of the tibial insert 414 is adjacent to and engagedwith the upper surface 442 of the platform 420 of the tibial tray 412.As such, the outer rim 440 of the tibial tray 412 surrounds a portion ofthe platform 454 of the tibial insert 414 in order to prevent rotationof the tibial insert 414 relative to the tibial tray 412.Illustratively, the platform 454 of the tibial insert 414 may includeone or more locking tabs 455 to be received within grooves or slots 457formed in the outer rim 440 of the tray 412 in order to further fix thetibial insert 414 relative to the tray 412.

In a second, or rotating configuration, the spacer 413 is placed withinthe cavity 444 of the tibial tray 412 and the insert 414 is placed ontothe spacer 413. As shown in FIG. 14, the spacer 413 includes an uppersurface 460, a lower surface 462, and an aperture 464 formedtherethrough. In the rotating configuration, the lower surface 462 ofthe spacer 413 is adjacent to and engaged with the upper surface 442 ofthe platform 420 of the tibial tray 412. Further, the upper surface 460of the spacer 413 is generally aligned or flush with an upper surface466 of the outer rim 440 of the tibial tray 412. The stem 450 of thetibial insert 414 is received through the aperture 464 of the spacer 413and into the bore 430 of the tibial tray 412 such that the bottomsurface 452 of the tibial insert 414 is adjacent to and engaged with theupper surface 460 of the spacer 413.

In the second configuration, the tibial insert 414 is able to rotaterelative to both the tibial tray 412 and the spacer 413. The spacer 413remains generally stationary relative to the tibial tray 412. As such,the tibial tray 412 and the tibial insert 414 shown in FIG. 14 cooperateto define a non-rotating tibial assembly while the tibial tray 412, thetibial insert 414, and the spacer 413 cooperate to define a rotatingtibial assembly.

Looking now to FIG. 15, another knee prosthesis system is provided. Theknee prosthesis system includes a tibial tray 512 and a fixed tibialinsert 514. A rotating tibial insert (not shown) similar to the tibialinsert 414 provided in FIG. 14 may also be included in this kneeprosthesis system. As with many of the other tibial trays disclosedherein, the tibial tray 512 shown in FIG. 15 includes a stem 522, aplatform 520, and a cavity or bore 530 formed to receive a portion ofthe tibial insert 514 therein. The fixed tibial insert 514 includes abearing 532 defining an upper bearing surface 534. Illustratively, thebearing 532 is made of a polymer such as ultra high molecular weightpolyethylene (UHMWPE), for example. The fixed tibial insert 514 furtherincludes a base or base plate 536 coupled to the bearing portion 532.Illustratively, the base 536 includes a backing 538 coupled to thebearing 532 and a stem 540 coupled to the backing 538. Illustratively,the base 536 is made from a metal such as titanium or cobalt chromium,for example. As shown in FIG. 15, a macro-texturized layer 539 of thestem portion 536, such as Porocoat® porous coating, for example,provides a surface into which the UHMWPE bearing 532 may be compressionmolded. The macro-texturized layer 539 operates to provide a physicalinterlock between the bearing 532 and the metal base 536. Alternatively,a bonding agent may be used to adhere the bearing component 532 to themetal base 536. Such techniques are discussed within U.S. PatentApplication Publication No. US 2006/0155383, titled ORTHOPAEDIC BEARINGAND METHOD FOR MAKING THE SAME, the disclosure of which is herebyincorporated by reference herein.

The stem 540 of the base 536 as well as the bore 530 of the tibial tray512 are each provided with coordinating metal-to-metal Morse tapers inorder to lock the two components together in a fixed relationship. Inother words, when the stem 540 of the fixed tibial insert 514 ispress-fit into the bore 530 of the tibial tray 512, the Morse taper ofthe bore 530 and stem 540 operate to prevent relative movement betweenthe insert 514 and the tray 512 to prevent rotating movement of theinsert 514 relative to the tray 512. The metal base 536 of the fixedtibial insert 514 may also prevent “cold flow” of the insert 514 intothe bore 530 of the tray 512. Further, it is contemplated that the metalbase 536 may operate to provide stiffness to the UHMWPE bearing 532including the bearing surface 534 in order to minimize stress on thetibial insert 514.

A separate all-poly tibial insert (not shown), such as the tibial insert414 shown in FIG. 14, may be used with the tray 512 of FIG. 15 in orderto provide a rotating tibial assembly.

Looking now to FIGS. 16 and 17, another knee prosthesis system isprovided. The knee prosthesis system includes a modular tibia tray foruse with a tibial insert (not shown), such as the tibial insert shown inFIG. 14, for example, which may be configured as a fixed tray (see FIG.16) whereby the tibial insert is prevented from rotating relative to thefixed tray or as a mobile tray (see FIG. 17) whereby the tibial insertis able to rotate relative to the rotating tray.

The modular tibial tray includes a stem or keel portion 610 a hubportion 612, a non-rotating platform 616 (shown in FIG. 16) and arotating platform 618 (shown in FIG. 17). A threaded screw 643 is alsoprovided in order to couple the hub portion 612 and the stem portion 610together. The stem portion 610 includes a bore 620 configured to receivethe hub portion 612 therein. The hub portion 612 may be press-fit intothe bore 620 of the stem portion 610. Illustratively, the screw 643 maybe received into and partially through the bore 630 of the hub portionto be threaded into a recessed bore 621 of the stem portion 610. The hubportion 612 includes a bore 630 configured to receive the stem of atibial insert (not shown) therein. The hub portion 612 further includesa threaded neck 632, as shown in FIGS. 16 and 17.

The fixed platform 616 shown in FIG. 16 includes a bottom wall 640 andan outer rim 642 extending upwardly from the bottom wall 640 around theperiphery of the bottom wall 640 to define a cavity 644 therein. Athreaded aperture 646 is formed through the bottom wall 640 of the fixedplatform 616. When the non-rotating tibial tray is assembled, the hubportion 612 is press-fit into the bore 630 of the stem portion 612and/or coupled to the stem portion by the screw 643 while the platform616 is threaded onto the neck 632 of the hub portion 612. As such, thestem of the tibial insert (not shown) is received into the bore 630 ofthe hub portion 612 such that the bottom surface of the platform of thetibial insert is adjacent to and engaged with the upper surface of thebottom wall 640 of the fixed platform 616. At least a portion of theplatform of the tibial insert is received within the cavity 644 of thefixed platform 616 in order to prevent rotation of the tibial insertrelative to the fixed platform 616.

Looking now to FIG. 17, the modular tibial tray further includes therotating platform 618 configured for use with a tibial insert, such asthe tibial insert shown in FIG. 14, for example. The rotating platform618 includes a threaded aperture 650 configured to receive the threadedneck 632 of the hub portion 612 in order to coupled the hub portion 612with the rotating platform 618. In this configuration, the stem of atibial insert is received through the aperture 650 of the rotatingplatform 618 and into the bore 630 of the hub portion 612. A bottomsurface of the tibial insert is positioned adjacent to and engaged witha top surface 652 of the rotating platform 618 such that the tibialinsert is able to rotate relative to the rotating platform 618.

Therefore, a fixed tibial assembly includes the fixed tibial tray 680shown in FIG. 16 as well as a tibial insert, such as the tibial insertshown in FIG. 14, for example. Alternatively, a rotating tibial assemblyof the prosthetic knee system shown in FIGS. 16 and 17 includes arotating tibial tray 682 shown in FIG. 17 as well as a coordinatingtibial insert, such as the tibial insert shown in FIG. 14, for example.

Looking now to FIGS. 18-21, a prosthetic knee system includes a tibialtray 712 and a tibial insert 714. The tibial tray 712 includes aplatform 720, a stem 722 coupled to the bottom surface 724 of theplatform 720 and a bore 730 configured to receive a stem of the tibialinsert 714 therein. The platform 720 includes a track defining grooves732 formed in the upper surface 734 of the platform 720, as shown inFIGS. 18 and 21, for example. Similar to the tibial insert 514 shown inFIG. 15, the tibial insert 714 includes a bearing portion 736 definingan upper bearing surface 738 and a stem portion 720 coupled to thebearing portion 736. Illustratively, the bearing portion 736 is made ofa polymer such as UHMWPE, for example. The stem portion 740 includes abacking 742 coupled to the bearing portion 736 and a stem 744 coupled tothe backing 742. Illustratively, the stem portion 740 is made from ametal such as titanium or cobalt chromium, for example. The stem portion740 further includes two curved rails 750 coupled to the bottom surfaceof the backing 742 of the stem portion 740, as shown in FIGS. 18 and 19,for example.

In use, the stem 744 of the tibial insert 714 is received within thebore 730 of the tibial tray 712 and the rails 750 are each receivedwithin the corresponding grooves or tracks 732 formed in the platform720 of the tibial tray 712 such that the bottom surface 760 of theplatform 742 of the tibial insert 714 is adjacent to and engaged withthe upper surface of the platform 720 of the tibial tray 712. In thisconfiguration, the tibial insert 714 is able to rotate relative to thetibial tray 712 about a longitudinal axis through the stem 722 of thetibial tray 712. The rails 750 and the tracks 732 operate to guide andconstrain such rotational movement of the insert 714 relative to thetray 712. In order to fix the tibial insert 714 relative to the tibialtray 712, a threaded screw 770 may be inserted through a countersunkbore 772 through the platform 720 of the tibial tray 712 and into athreaded bore 774 formed in the bottom surface 760 of the platform 742of the tibial insert 714. As such, the tibial insert 714, the tibialtray 712, and the locking screw 770 cooperate to provide a non-rotatingtibial assembly while the tibial insert 714 and the tibial tray 712cooperate to provide a rotating tibial assembly, as discussed above. Asshown in FIG. 20, an alternative rail 780 of the tibial insert 714provides a closed path around a perimeter of the platform 742. Thisalternative rail 780 is provided for use with an alternative tibial trayto provide a fixed tibial assembly without the use of any threaded screw770, as is discussed below in regards to FIG. 87.

As noted above, the stem portion 740 of the tibial insert 714 is madefrom metal such that the rail(s) 750 or 780 of the stem portion 740is/are made from metal as well in order to slide within thecorresponding metal tracks 732 of the tibial tray 712. Alternatively,the metal rail(s) 750 or 780 may be molded directly into the bottomsurface of the polymer bearing portion 736 of the insert 714 without theuse of the metal backing 742 of the stem portion 740.

Looking now to FIG. 86, alternative rails or tabs 790 of the tibialinsert 714 and alternative tracks or grooves 792 of the tibial tray 712are provided. Similar to the rails 750 and corresponding grooves 732described above in regards to FIGS. 18, 19, and 21, the tabs 790 andtracks 792 operate to guide and constrain rotational movement of theinsert 714 relative to the tray 721. Further, similar to that shown inFIG. 18, a locking screw 770 may be provided to fix the relativemovement between the tibial insert 712 and the tray 714. Alternatively,the tabs 790 may have a tab or projection (not shown) to be receivedwithin an undercut feature (not shown) of the corresponding tracks 792in order to prevent lift-off of the tibial insert 712 relative to thetray 714.

Looking now to FIG. 87, a prosthetic knee assembly includes a rotatingtibial insert 794 having a platform 796 and a stem 798 coupled thereto.The tibial insert 714 having the continuous rail 780 about the perimeterof the platform 742 (also shown in FIG. 20) provides the fixed tibialinsert. A tibial tray 800 may be used with either the rotating tibialinsert 794 or the fixed tibial insert 714. Illustratively, the tibialtray 800 includes the platform 720, the stem 722 coupled thereto, andthe bore 730 formed through the platform 720 and into the stem 722. Arecessed track 802 is formed around the perimeter of the top surface 734of the platform 720. The track 802 defines a closed path and correspondsin size and shape to the continuous track or rail 780 of the fixed tray714 shown in FIGS. 20 and 87. Illustratively, the insert 714 includes acenter hub or ring 741 configured to be received within a recessedportion 743 formed in the platform 720 of the tray 800 around the bore730. Illustratively, the track 780 of the insert 714 is made of metaland is formed integrally with the metal backing 742 compression moldedto the polymer platform portion 736. Alternatively, the metal track 780may be compression molded directly to the polymer platform portion 736.In use, the stem 798 of the rotating tibial insert 794 may be insertedinto the bore 730 of the tibial tray 800 to provide a rotating tibialassembly. Alternatively, the hub 741 and rail 780 of the fixed tibialinsert 714 may be received within the corresponding recessed portion 743and track 802 of the tibial tray to prevent rotation of the tibialinsert 714 relative to the tray 800. The fixed tibial insert 714 mayfurther include one or more flexible tabs (not shown) while the tibialtray 800 may include an undercut portion (not shown) in order to receivethe flexible tabs therein and further couple the fixed tibial insert 714to the tray 800.

Looking now to FIGS. 22 a, 22 b, and 23, another prosthetic kneeassembly includes a tibial tray 812, a tibial insert 814, and fourlocking posts 816. Illustratively, the tibial tray 812 and the tibialinsert 814 (without use of the posts 816) cooperate to provide arotating tibial assembly while the tibial tray 812, tibial insert 814,and the posts 816 cooperate to prove a fixed tibial assembly.

Illustratively, the tibial tray 812 includes a platform 820 and a stem822 coupled to a bottom surface 824 of the platform 820. Four threadedbores 826 are formed in the upper surface 828 of the platform 820. Thetibial insert 814 includes a platform 840 having an upper bearingsurface 842 and a stem 844 coupled to a bottom surface 846 of theplatform 840. Four countersunk bores 850 are formed in the bottomsurface 846 of the platform 840. Each locking post 816 includes athreaded stem 860, a hexagonal washer 862, and a slotted head 864.

In a first configuration providing the fixed tibial assembly, each post816 is threaded into a respective threaded bore 826 of the platform 820of the tibial tray 812 such that the hexagonal washer 862 is engagedwith the upper surface 828 of the platform 820. The stem 844 of thetibial insert 814 is received within the bore 830 of the tibial tray 812and the platform 840 of the tibial insert 814 is snapped onto theexposed heads 864 of the posts 816 such that each head 864 is receivedwithin a respective bore 850 of the platform 840 of the tibial insert814. Illustratively, the head 864 of each post 816 is slotted such thatportions of each head 864 may deflect or collapse inwardly duringinstallation to create a bias upon the inner wall of the respective bore850 within which each post 816 is received. In other words, the size ofeach bore 850 is smaller than the un-collapsed size of each head 864 inorder to maintain the respective head 864 in slight compression withinthe bore 850 to assist in retaining the insert 814 against the tray 812.In such a configuration, the tibial insert 814 is prevented fromrotating relative to the tibial tray 812. In a second configuration, theposts 816 are not coupled to the tibial tray 812 and the tibial insert814, when received upon the tray 812, is permitted to rotate relative tothe tibial tray 812. In such a configuration, the bores 850 of thepolymer tibial insert 814 may be filled or plugged with a metal post(not shown) in order to prevent any cold flow of the polymer platform840 into the bores 850 when the locking posts 816 are not being used.Accordingly, The posts 816 may be selectively used to convert theprosthetic knee system from a rotating tibial assembly to a fixed tibialassembly.

Illustratively, as shown in FIG. 22 a, the threaded bores 826,countersunk bores 850, and locking posts 816 are positioned generallyunder a load bearing portion (i.e., below the condylar surfaces 842) ofthe tibial insert 814. Alternatively, as shown in FIG. 22 b, two of thethreaded bores 826 of the tray 812 may be positioned anteriorly andposteriorly of the bore 830 and within close proximity to the bore 830while two other threaded bores 826 may be positioned medially andlaterally of the bore 830 near an outer periphery of the platform 820 ofthe tray 812. Accordingly, the countersunk bores 850 of the tibialinsert 814 may be located in positions which correspond to thealternatively placed bores 826. As such, the locking posts 816 receivedwithin the alternatively placed bores 826, 850 are not positioneddirectly under any major load bearing portions of the tibial insert 814.

Looking now to FIG. 24, another prosthetic knee system includes thetibial tray 312 of FIGS. 10-13, a metal ring 914, and a tibial insert916 similar to the tibial insert 314 shown in FIGS. 12 and 13. Theprosthetic knee system shown in FIG. 24 is similar to that shown inFIGS. 10-13; as such, like reference numerals have been used to denotelike components. In particular, FIG. 24 shows the tibial tray 312 shownin FIG. 12 which may be used either with the tibial insert 314 shown inFIGS. 10-11 to provide a fixed tibial assembly or with the tibial insert316 shown in FIG. 12-13 to provide a rotating tibial assembly. Further,as shown in FIG. 24, the tibial tray 312 may be used with the metal ring914 which is sized to rest upon the outer ledge 344 of the lowerplatform 342 in order to surround the upper platform 340 and ispositioned such that an upper surface 916 of the metal ring 914 isgenerally flush with the upper surface 376 of the upper platform 340. Assuch, the metal ring 914 effectively operates to increase the footprintor size of the surface upon which the platform of any tibial insert mayrest. By increasing the size of this surface, a tibial insert, such asthe tibial insert 916 shown in FIG. 24, which has a platform 970 havinga footprint larger than that of the platform 370 of the tibial insert316 shown in FIG. 12, for example, may be used. In other words, a widertibial insert, such as the tibial insert 916, having a bottom platformsurface defining a larger platform surface area may be used. As such,the metal ring 914 allows the tibial tray 312 to be used with tibialinserts of varying sizes.

Looking now to FIGS. 25-26, still another prosthetic knee assembly isprovided. Various components of the prosthetic knee assembly of FIGS.25-26 are the same as or similar to the components shown in FIGS. 10-11;as such, like reference numerals are used to denote like components. Atibial tray 912 shown in FIGS. 25 and 26 includes a platform 920 and astem 922 coupled to the bottom surface 924 of the platform 920. Theplatform 920 includes a center stepped section to define an upperplatform 940 and a lower platform 942. The lower platform 942 is largerthan the upper platform 940 to define an outer ledge 944 of the platform920.

The fixed tibial insert 314 includes the recess 348 to receive the upperplatform 940 of the tibial tray 912 therein. In such a position, thefixed tibial insert 314 is prevented from rotating relative to the tray912. As shown in FIGS. 25 and 26, the tibial insert 314 is sized suchthe lower platform 942 of the tibial tray 912 extends beyond an outerperimeter of the tibial insert 314. A locking metal ring 980 is furtherprovided to fit around the fixed tibial insert 314, as shown in FIG. 26.Illustratively, the metal ring 980 is sized for positioning on theportion of the ledge 944 of the lower platform 942 of the tibial tray912 which extends beyond the outer perimeter of the tibial insert 314.In this position, an outer surface 982 of the metal ring 980 isgenerally flush with the outer surface 984 of the lower platform 942 ofthe tray 912. The locking metal ring 980 may be friction-fit, taper-fit,or snap-fit around the tibial insert 314 in order to further prevent therotational movement of the tibial insert 314 relative to the tibial tray912 as well as any micro-motion between the two components.

Looking now to FIGS. 27-29, another prosthetic knee assembly includes atibial tray 1012, a tibial insert 1014, and a set screw 1016. The tibialtray 1012 includes a platform 1020, a stem 1022, and a bore 1030 throughthe platform 1020 and into the stem 1022. The tibial insert 1014similarly includes a platform 1040, a stem 1042, and a tapered bore 1044through the platform 1040 and the stem 1042. The stem 1042 of the tibialinsert 1014 includes an outer rim 1046. Further, the distal end of thebore 1044 is threaded to include threads 1048, as shown in FIG. 27.Looking to FIG. 29, the distal end of the stem 1042 of the tibial insert1014 further includes a slit 1050 to allow the distal end of the stem1042 to be narrowed and widened. The set screw 1016 includes outerthreads 1052.

In a first, rotational configuration, the stem 1042 of the tibial insert1014 is received within the bore 1030 of the tibial tray 1012 such thatthe annular, outer rim 1046 of the tibial insert 1014 is positionedwithin an annular groove 1060 formed in inner surface 1062 of the stem1022 of the tibial tray 1012. Without the use of the set screw 1016, thetibial insert 1014 is able to rotate relative to the tibial tray 1012about a longitudinal axis running through the stem 1022 of the tray1012. The outer rim 1046 of the tibial insert 1014 positioned within thegroove 1060 of the tibial tray 1012 aides in preventing lift-off of thetibial insert 1014 relative to the tibial tray 1012 during use.

In a second, fixed configuration, the set screw 1016 is received withinthe bore 1044 of the tibial insert 1014 and is threaded into the distalend of the tapered bore 1044 of the tibial insert 1014. As the set screw1016 is threaded distally within the tapered bore 1044, the distal endof the stem 1042 is forced to expand outwardly against the inner surface1062 of the stem 1022 of the tibial tray 1012. As such, the stem 1042 ofthe tibial insert 1014 becomes press-fit into the stem 1022 of thetibial tray 1012 in order to prevent rotational movement of the tibialinsert 1014 relative to the tibial tray 1012.

Looking now to FIGS. 30-33, a modular tibial insert 1114 for use with atibial tray (not shown) is provided. Illustratively, the tibial insert1114 includes a platform 1116, an anterior-posterior-glide (APG) stem1152 (shown in FIG. 33) for selective use with the platform 1116, and arotating-platform stem (RP) 1140 (shown in FIGS. 30 and 32) forselective use with the platform 1116 as well. Accordingly, the modulartibial insert 1114 disclosed in FIGS. 30-33 provides an APG tibialinsert including the platform 1116 and the APG stem 1152 as well asrotating or mobile tibial insert including the RP platform 1116 and thestem 1140. Illustratively, the modular tibial insert 1114 may be usedduring minimally-invasive or traditional knee replacement surgeries.

The platform 1116 includes an upper bearing surface 1118, a bottomsurface 1120, and an anterior/posterior track 1122 formed in the bottomsurface 1120 of the platform 1116. The anterior/posterior track 1122includes an angled or ramped portion 1130, as shown in FIG. 32, as wellas a straight portion 1132 which is generally parallel to the bottomsurface 1120 of the platform 1116. A notch 1134 is further formed withinthe anterior/posterior track 1122, as shown best in FIG. 31.

The RP stem 1140 includes a tapered stem portion 1142, a head portion1144, and a narrowed neck portion 1146 coupled to and positioned betweenboth the stem portion 1142 and the head portion 1146. Illustratively,the head portion 1142 is generally axially symmetrical about alongitudinal axis along the stem portion 1144. In use, the RP stem 1140is first inserted into a bore formed in a corresponding tibial tray (notshown) and the platform 1116 is slid onto the head portion 1144 of theRP stem 1140. In other words, the head portion 1144 of the stem 1140 ispositioned within the track 1122 and travels along the track 1122 to acentral location of the track 1122 where the head portion 1144 is lockedinto place relative to the platform 1116 to provide a rotating tibialinsert able to rotate about an axis through the stem 1140 relative tothe tibial tray upon which it rests.

As noted above, the modular tibial insert of FIGS. 30-33 furtherincludes an anterior-posterior-glide (APG) stem 1152 (shown in FIG. 33)including a tapered stem portion 1152, a head portion 1154, and anarrowed neck portion 1156 coupled to and positioned between both thestem portion 1152 and the head portion 1154. As shown in FIG. 33, thehead portion 1152 includes a posteriorly-extending glide arm 1160. Aremovable stopper 1162 may be selectively coupled to an anterior end ofthe arm 1160 and/or received within an anterior notch 1134 of the track1122 of the platform 1116.

In use, the APG stem 1150 is first inserted into a bore formed in acorresponding tibial tray (not shown) and the platform 1116 is slid ontothe head portion 1154 of the APG stem 1150 such that the glide arm 1160is positioned within the track 1122. The removable stopper 1162 may thenbe positioned either within the notch 1134 formed in the track 1122 ofthe platform 1116 or on the anterior end of the glide arm 1160. Thestopper 1162 operates to prevent anterior motion of the platform 1116relative to the APG stem 1150 beyond a certain predetermined point whileposterior motion of the platform 1116 relative to the APG stem isillustratively not limited. Illustratively, the APG insert describedherein is similar to other known APG inserts disclosed in U.S. PatentApplication Publication Nos. US2004/0204765 and US2003/0195634 eachtitled PROSTHETIC KNEE WITH REMOVABLE STOP PIN FOR LIMITING ANTERIORSLIDING MOVEMENT OF BEARING, for example.

Looking now to FIGS. 34 a, 34 b, and 35, another prosthetic knee systemincludes a fixed tibial insert 1214, a mobile tibial insert 1215, and atibial tray 1212. The tibial tray 1212 includes a platform 1220 and astem 1222 coupled to a bottom surface 1224 of the platform 1220. Medialand lateral rails 1244 of the tibial tray 1212 extend upwardly from anupper surface 1246 of the platform 1220. Illustratively, the peripheralrails 1244 are positioned laterally or outwardly from the center of thetray 1212. As is discussed below, the rails 1244 operate as a peripheralcapture mechanism to maintain the fixed tibial insert 1214 therein.Further, each peripheral rail 1244 includes a notch or recess 1248, asshown in FIG. 35.

The fixed tibial insert 1214, shown in FIGS. 34 a and 35 includes aplatform 1250 and a stem 1252 configured to be received within a cavityor bore 1230 of the tray 1212. The platform 1250 of the insert 1214further includes flexible tabs 1260 extending from a side wall 1262 ofthe platform 1250. Illustratively, the platform 1250 of the fixed insert1214 is sized to be received within the peripheral rails 1244 of thetray 1212 such that the flexible tabs 1260 are received within thecorresponding notches 1248 of each wall 1244. As such, the outer,peripheral rails 1244 of the tray 1212 create a partial “skirt” tocontain the tibial insert 1214 therein and to prevent rotation of thetibial insert 1214 relative to the tibial tray 1212. The notches 1248and corresponding tabs 1260 operate to further couple the insert 1214 tothe tray 1212 to prevent lift-off of the insert 1214 relative to thetray 1212 during use.

The rotating tibial insert 1215, shown in FIG. 34 b, includes a platform1270 smaller than the platform 1250 of the fixed tibial insert 1215 suchthat clearance or space between the peripheral rails 1244 of the tray1212 and the platform 1270 allows the platform 1270 to rotate relativeto the tray 1212. In other words, the platform 1270 of the rotatingtibial insert 1215 is sized to enable the insert 1215 to rotate withinthe periphery capture mechanism, or rails 1244, of the tibial tray 1212.Accordingly, the tibial insert 1215 and the tray 1212 cooperate toprovide a rotating tibial assembly.

Looking now to FIGS. 36-39, another prosthetic knee assembly includes amodular tibial tray assembly including a platform 1312 (shown in FIGS.36 and 38), a rotating-insert stem 1314 (shown in FIG. 36), afixed-insert stem 1316 (shown in FIGS. 37 and 38), and a revision stem1318 (shown in FIG. 40). In a first configuration, a threaded aperture1320 of the platform 1312 is threaded onto a threaded proximal end 1322of the rotating-insert stem 1314. In such a configuration, the platform1322 and stem 1314 cooperate to provide a tibial tray 1330 for use witha tibial insert (such as the tibial insert 414 shown in FIG. 14, forexample) which is able to rotate relative to the tibial tray 1330.

In another configuration, the platform 1312 is coupled to thefixed-insert stem 1316. The fixed-insert stem 1316 includes a stemportion 1340 having a threaded proximal end 1342 and a T-shaped headportion 1344 coupled to the proximal end 1342 of the stem 1316. Thethreaded aperture 1320 of the platform 1312 is threaded onto theproximal end 1342 of the stem 1316 such that the head portion 1344 ofthe stem 1316 is positioned above an upper surface 1346 of the platform1312. In such a configuration, the platform 1312 and the fixed-insertstem 1316 cooperate to provide a tibial tray 1348 for use with a tibialinsert 1350 as discussed below.

The fixed tibial insert 1350, as shown in FIG. 38, includes a bottomsurface 1352, an upper bearing surface 1352 and a T-shaped bore 1356formed in the bottom surface 1352 of the insert 1350. The fixed tibialinsert 1350 may be snapped onto the fixed-insert stem 1316 such that thehead portion 1344 of the stem 1316 is received within the bore 1356 ofthe fixed tibial insert 1350. Illustratively, the head portion 1344 ofthe stem 1316 may be square-shaped or generally non-circular in shapewhen viewed in a plan view while the corresponding bore 1356 of thefixed tibial insert 1350 may define a coordinating shape formed toreceive the head portion 1344 therein. By providing a non-circular shapeof the head portion 1344 and the bore 1356, the fixed tibial insert 1350is prevented from rotating relative to the tray 1348.

Illustratively, the stem portion 1340 of the fixed-insert stem 1316 issplined, as shown in FIG. 39, such that the stem portion 1340 may becompressed and expanded as desired. Further, the prosthetic kneeassembly shown in FIGS. 36-40 includes the revision stem 1318 having athreaded proximal end 1360, as shown in FIG. 40. Similar to thatdescribed above, the platform 1312 may be threadably coupled to therevision stem 1318 for use as a revision tibial tray.

Looking now to FIGS. 41 and 42, a prosthetic knee system includes atibial tray 1412, a tibial insert 1414, and four locking posts 1416. Ina first configuration, a stem 1420 of the tibial insert 1414 is receivedwithin a bore 1430 of the tibial tray 1412. The tibial insert 1414includes four through-holes 1432 extending from an upper bearing surface1434 to a bottom surface 1436 of the platform 1438 of the insert 1414.The holes 1432 of the tibial insert 1414 are aligned with fourthrough-holes 1440 of the tibial tray 1412 which each extend from a topsurface 1442 to a bottom surface 1444 of the platform 1446 of the tray1412. One of the posts 1416 is then received within the holes 1432, 1440of the tibial insert 1414 and the tibial tray 1412 in order to preventrotation of the tibial insert 1414 relative to the tibial tray 1412. Assuch, the tibial insert 1414, the tibial tray 1412, and the lockingposts 1416 cooperate to provide a fixed tibial assembly. Illustratively,the locking posts 1416 may be metal locking posts.

Additionally, as shown in FIG. 41, a surgeon or other technician maydrill bores 1450 into the surgically-prepared surface 1452 of thepatient's tibia 1454 upon which the platform 1446 of the tibial tray1412 rests. Such bores 1450 may be positioned to align with thethrough-holes 1432, 1440 of the insert 1414 and tray 1412 in order toreceive a portion of one of the posts 1416 therein. Illustratively, inorder to prevent lift-off of the insert 1414 relative to the tray 1412,the posts 1416 and coordinating holes 1432, 1440 may be configured toprovide a press-fit, slip-fit, taper-fit, or threaded lockingconnection.

Of course, the tibial tray 1412 may include blind holes (not shown)formed in the top surface 1442 of the platform 1446 of the tray 1412rather than the through-holes 1440 shown. As such, it becomesunnecessary to drill aligning bores into the patient's tibia 1454 andshorter posts may be received through the platform 1438 of the tibialinsert 1414 and into the blind holes of the tibial tray. Further, thetibial insert 1414 may include blind holes (not shown) formed into thebottom surface 1436 of the platform 1438 of the tibial insert 1414rather than the through-holes 1432 shown in FIG. 41. Pins (not shown)may then be provided which are received into the blind holes such thatthe tibial insert with the pins extending downwardly therefrom may besnapped into the blind holes formed in the tray in order to couple theinsert to the tray and prevent relative rotational movementtherebetween.

Looking now to FIG. 88, alternative locking post designs which may beused in addition to or in place of the locking posts 1416 are providedfor use with the prosthetic knee system of FIGS. 41 and 42. For example,a first alternative locking post 1460 includes a body 1462 and athreaded head 1464 coupled to the body 1462. Accordingly, thecorresponding through-hole 1432 of the tibial insert 1414, includes athreaded insert 1466 (or any threaded end) such that the threaded head1464 of the post 1416 may be threaded into the insert 1466 in order tosecure the post 1461 to the tibial insert 1414. A second alternativelocking post 1470 includes a body 1472 and a head 1474 having a lockingflange 1476. Accordingly, the corresponding through-hole 1432 includes acut-out portion 1478 to receive the head 1474 and locking flange 1476 ofthe post 1470 therein in order to prevent relative movement of the pin1470 and the tibial insert 1414. Finally, a third alternative lockingpost 1480 includes a body 1482 and a knurled head 1484 coupled to thebody 1482 such that the knurled outer surface of the head 1482 may bepress-fit and secured to the smooth inner walls of the correspondingthrough-hole 1432 formed in the polymer insert 1414. Similar to thelocking posts 1416, the alternative locking posts 1460, 1470, and 1480may be metal as well. As further noted in FIG. 88, the through-holes1432 formed in the tibial insert 1414 may form rounded edges, ratherthan sharp edges, within the bearing surface 1434 of the platform 1438of the insert 1414. Further, while the through-holes 1432 of the insert1414 and the corresponding holes 1440 of the tray 1412 are shown inparticular locations, it is within the scope of this disclosure toorient or position any number of holes 1432, 1440 for receiving variouslocking pins in any suitable location within the insert 1414 and thetray 1412.

While various locking pins have been shown, it is within the scope ofthis disclosure to include locking pins which are press-fit, slip-fit,threaded, knurled, tapered, or which include any other suitable lockingfeature to enable the pins to be fixedly coupled to the tibial insert.As noted above, it is within the scope of this disclosure for thepatient's tibia 1454 to be prepared to accept locking pins therein(i.e., including bores 1450 drilled into the surface 1452) or to benon-prepared (i.e., without bores 1450 drilled into the surface 1452) inwhich case the locking pins may be sized of a suitable lengthaccordingly. Further, the tibial insert 1414 may be configured toinclude a blind hole or holes (not shown) formed in the bottom surface1436 of the platform 1438 (rather than the through-holes 1432) withinwhich the locking pin(s) may be received and the tibial tray 1412 maysimilarly be configured to include a blind hole or holes (not shown)formed in the top surface 1442 of the platform 1446 of the tray 1412(rather than the through holes 1440) within which the locking pin(s) maybe received. Further, while the locking pins 1416, 1460, 1470, 1480 areshown as separate components, it is within the scope of this disclosurefor such locking pins to be integral with or compression molded into theunderside or bottom surface 1436 of the platform 1438 of the insert 1414to provide a fixed tibial insert. With such a configuration, a separaterotating tibial insert may be provided for use with the tray 1412 inorder to provide a rotating tibial assembly.

In another configuration of the prosthetic knee system shown in FIGS.41, 42, and 88 the tibial insert 1414 may be used with the tibial tray1412 without the use of the posts 1416, 1460, 1470, 1480. As such, thetibial insert 1414 is able to rotate relative to the tibial tray 1412 toprovide a rotating tibial assembly. Metal plugs (not shown) may beprovided to fill the through-holes 1432 in order to prevent any possiblecold flow of the polymer platform 1438 into the holes 1432.

Looking now to FIGS. 43-46, a modular tibial insert system includes aplatform 1512 (shown in FIGS. 43 and 44) and a stem 1514.Illustratively, the stem 1514 may be converted for use as ananterior-posterior-glide (APG) stem and a rotating-platform (RP) stem.Illustratively, the platform 1512 includes an upper bearing surface 1518and a bottom surface 1520. A track 1522 is provided in the bottomsurface 1520 of the platform 1512. Illustratively, the track 1522extends along an anterior/posterior direction and is generally T-shapedwhen viewed is cross-section, as shown in FIG. 44, to include a narrowedneck portion 1526 and a wider head portion 1528.

The stem 1514 of the modular tibial insert system includes a stemportion 1515, a threaded neck 1517 movable up and down relative to thestem portion 1515, and a guide arm 1516 coupled to the neck 1517.Illustratively, the guide arm 1516 includes an internal shaft 1519 incommunication with the neck 1517 to create a worm gear therebetween. Theshaft 1519 may be rotated clockwise or counterclockwise using an Allenwrench, for example, in order to move the neck 1517 upwardly ordownwardly relative to the stem portion 1515 in order to convert thestem 1514 from an RP stem to an AGP stem, as is discussed below.

The track 1522 of the platform 1512 is configured to receive the guidearm 1516 therein. When the neck 1517 of the stem 1514 is in a loweredposition (not shown), such that the upper end of the neck 1517 ispositioned in-line with or below the guide arm 1516, the platform 1512is free to move in an anterior/posterior direction to define an APGtibial insert. The track 1522 and coordinating guide arm 1516 operate toguide the anterior/posterior movement of the platform 1512 on the stem1516.

Alternatively, the neck 1517 of the stem 1514 may be moved to a raisedposition, as shown in FIGS. 45 and 46, for example, once the guide arm1516 is received within the track 1522 of the platform 1522. In theraised position, the upper end of the neck 1517 of the stem 1514 isreceived within a central bore 1524 formed in the platform 1512. In sucha configuration, the platform 1512 is prevented from moving in ananterior/posterior direction relative to the stem 1514. Accordingly, thestem 1514 and the platform 1512 form an RP tibial insert when the neck1517 of the stem is in the raised position.

Looking now to FIGS. 47 and 48, another prosthetic knee system includesa tibial tray 1612 and a collet 1614 received within a distal end 1616of the tibial tray 1612. As shown in FIG. 47, the tibial tray 1612includes a platform 1620, a stem 1622 coupled to a bottom surface 1624of the platform 1620, and a bore 1630 formed through the platform 1620and into the stem 1622. Illustratively, a distal end of the bore 1630includes both a tapered portion 1632 and a threaded portion 1634, asshown in FIG. 47.

The collet 1614 is positioned within the distal end of the bore 1630 andincludes a tapered head portion 1640 and a threaded body portion 1642configured to be threaded into the threaded portion 1634 of the bore1630. The collet 1614 includes a central bore 1650 and multiple slots1652 formed through the tapered head portion 1640 to permit the outerwall portions of the tapered head portion 1640 of the collet 1614 to becompressed or expanded as discussed in greater detail below. The collet1614 may also include a hexagonal bore 1660 in communication with thecentral bore 1650 for use with a hexagonal wrench or other similar tool,as is discussed below.

In use, the stem of a tibial insert (not shown) is received within thebore 1630 of the tibial tray 1612 such that a distal end of the stem ofthe tibial insert is received within the central bore 1650 of the collet1614. The collet 1614 may be tightened or loosened to prevent or permitrotation of the tibial insert relative to the tibial tray 1612, asdiscussed below. Illustratively, the tibial insert may include a boreformed therethrough such that a hexagonal wrench may be received throughthe platform and stem of the tibial tray to engage the hexagonal bore1660 of the collet 1614 in order to tighten or loosen the collet 1614.

In the tightened position, collet 1614 is moved upwardly within the bore1630 of the tibial tray such that the tapered walls 1632 of the bore1630 of the tibial tray 1612 urge the tapered head portion 1640 of thecollet 1614 to compress around the distal end of the stem of the tibialinsert received within the central bore 1650 of the collet 1614 in orderto prevent relative rotational movement therebetween. In other words,the tapered head portion 1640 of the collet 1614 is flexible and is ableto be squeezed or contracted around the distal end of the stem of thetibial insert when moved upwardly within the bore 1630. Alternatively,when the collet 1614 is moved downwardly within the bore 1630, thetapered head portion 1640 of the collet 1614 is able to expand andloosen its grip on the distal end of the tibial insert 1612. As such,the untightened, or downward position, the collet 1614 does notsubstantially interfere with the rotating motion of the tibial insertrelative to the tray 1612.

Looking now to FIGS. 49 and 50, a tibial assembly 1710 includes a tibialtray 1712 and a rotating tibial insert 1714. The rotating tibial insert1714 includes a bearing portion 1716 defining an upper bearing surface1718. Illustratively, the bearing portion 1716 is made of a polymer suchas UHMWPE, for example. The tibial insert 1714 further includes a metalbacking portion 1720 coupled to the bearing portion 1716 and includes apair of rails 1730 extending downwardly from a bottom surface 1732 ofthe metal backing portion 1720.

The tibial tray 1712 includes a platform 1740 and a stem 1742 coupled toa bottom surface 1744 of the platform 1740. The platform 1740 furtherincludes a roller bearing system 1750 incorporated into a top surface1752 of the platform 1740. Illustratively, the roller bearing system1750 includes a plurality of roller bearings 1754 set in a circulartrack 1756 coupled to the platform 1740. The platform 1740 furtherincludes a pair of guide tracks 1760 formed to receive thedownwardly-extending rails 1730 of the tibial insert 1714 therein. Theroller bearings 1754 of the roller bearing system 1750 are metal and areadjacent to and engaged with the bottom surface 1732 of the metalbacking portion 1720 of the tibial insert 1714. As such, the rollerbearing system 1750 operates to decrease friction between the tibialinsert 1714 and the tibial tray 1712 as the tibial insert 1714 is urgedto rotate relative to the tibial tray 1714. The guide tracks 1760 andthe rails 1730 cooperate to guide and constrain the rotational movementof the tibial insert 1714 relative to the tibial tray 1712.

Looking now to FIG. 51 a, a fixed tibial insert 1814 for use with atibial tray (not shown) is provided. The tibial insert 1814 is similarto the tibial insert 214 shown in FIG. 2. As such, like referencenumerals have been used to denote like components. The tibial insert1814 of FIG. 51 a further includes flanges or pegs 1820 coupled to thedistal end of the stem 245. The pegs 1820 of the tibial insert 1814 areflexible and may be snapped into corresponding annular grooves formed inthe bore of the tibial tray (not shown) into which the stem 245 isreceived. The pegs 1820 aide in preventing lift-off of the tibial insert1814 relative to the tibial tray. In an alternative embodiment, the stem245 of the tibial insert 1814 may include flexible tabs 1860, as shownin FIG. 51 b, which may be received within corresponding slots or anannular groove formed into the bore of the stem of a correspondingtibial tray in order to prevent lift-off of the insert relative to thetray.

Looking now to FIGS. 52-54, a modular tibial tray is provided whichincludes a platform 1920, shown in FIGS. 52 and 53, and a stem 1922,shown in FIG. 54, which may be secured to the platform 1920 in a varietyof positions. Looking first to FIGS. 52 and 53, the platform 1920includes a top surface 1924, a bottom surface 1926, and a pair ofgenerally C-shaped guide tracks 1928 coupled to the bottom surface 1926of the platform 1920. The ends of each guide track 1928 are open to aninner channel or passageway 1930 of each track 1928. An opening or slot1932 is formed in a bottom wall 1926 between two inner-extending lips ofeach guide track 1928 to provide communication with the inner passageway1930. The stem 1922 includes a stem body 1940 and a mounting end havinga threaded neck 1942 extending upwardly from the stem body 1940. Alocking bolt 1944 of the stem 1922 is configured to be coupled to thethreaded neck 1942.

In use, the locking bolt 1944 is coupled to the threaded neck 1942 andreceived through one of the ends of one of the guide tracks 1928 of theplatform 1920 such that the neck 1942 of the stem 1922 is receivedthrough the slot 1934 of the particular guide track 1928 and the lockingbolt 1944 is received within the channel 1930. The stem 1922 may then bemoved along the chosen guide track 1928 to position the stem 1922 asdesired by the surgeon or other technician.

Once the stem 1922 is properly positioned relative to the platform 1920,the locking bolt 1944 may be tightened further onto the neck 1942 of thestem 1922 to prevent relative movement between the stem 1922 and theplatform 1920. In other words, the chosen guide track 1928 operates tocapture the locking bolt 1944 therein and once the stem 1922 is in thedesired position along the track 1928, the stem 1922 can be tightenedinto the locking bolt 1944 to fix the stem 1922 in place relative to theplatform. Illustratively, therefore, the modular tibial tray shown inFIGS. 52 and 53 provides an offset stem 1922 which may be positionedoff-center either medially or laterally on the platform 1920 and whichmay be positioned posteriorly or anteriorly along the particular offsetguide track 1928.

Looking now to FIGS. 55 and 56, a prosthetic knee assembly includes atibial tray 2012, a tibial insert 2014, and a pair of clamps 2016configured to be used with the tibial insert 2014 and the tibial tray2012 to provide a fixed tibial assembly. The tibial insert 2014 includesa platform 2020 having an annular groove 2022 formed in an outer,peripheral surface 2024, as shown in FIG. 56. The tibial tray 2012includes four threaded bores 2030 formed into an outer, peripheralsurface 2032 of a platform 2034 of the tray 2012. Each clamp 2016 isgenerally C-shaped to mate with the medial and lateral outer surfaces2024, 2032 of each of the tibial insert 2014 and the tibial tray 2012.Each clamp 2016 further includes a rim or lip 2040 protruding from aninner surface 2042 of each clamp 2016 as well as a pair of countersunkbores 2044 configured to receive a threaded screw 2050 therethrough.

In a first, fixed configuration, the clamps are positioned adjacent theouter, peripheral walls 2024, 2032 of the tibial insert 2014 and thetibial tray 2012 such that the rim 2040 of each clamp 2016 is receivedwithin the groove 2022 of the tibial insert 2014. Further, the bores2044 of each clamp 2016 are aligned with corresponding bores 2030 of thetibial tray 2014. One of the threaded screws 2050 is received througheach of the countersunk bores 2044 of the clamps 2016 and is screwedinto the respective threaded bore 2030 of the tibial tray 2014. As such,each clamp 2016 is coupled to the tibial tray 2012 and the tibial insert2014 in order to prevent rotational movement of the tibial insert 2014relative to the tibial tray 2012. The rim 2040 of each clamp 2016 andthe groove 2022 of the tibial insert 2014 cooperate to prevent lift-offof the tibial insert 2014 relative to the tibial tray 2012.Illustratively, each clamp 2016 may be metal. In a second, rotatingconfiguration, the clamps 2016 are not used and the tibial insert 2014is able to rotate relative to the tibial tray 2012 to provide a rotatingtibial assembly.

Looking now to FIGS. 57 and 58, another prosthetic knee assembly isprovided. The prosthetic knee assembly of FIGS. 57 and 58 is similar tothe prosthetic knee assembly of FIGS. 55 and 56. As such, like referencenumerals are used to denote like components. In general, the prostheticknee assembly of FIGS. 57 and 58 provides multiple clamps 2016 tosurround and capture a majority of the peripheral surfaces 2024, 2032 ofeach of the tibial insert 2014 and the tibial tray 2012 in order toprevent rotational movement of the tibial insert 2014 relative to thetibial tray 2012. Further, the tibial insert 2014 includes a V-shapedgroove 2082 formed in the outer surface 2024 of the platform 2020 andeach clamp 2016 includes a coordinating V-shaped rim or tab 2084 to bereceived within the V-shaped groove 2082 of the insert 2014. Thecoordinating V-shape designs of both the tab 2084 and the groove 2082may operate to provide downward pressure against the tibial tray 2012 tofurther aide in preventing lift-off and micromotion of the tibial insert2014 relative to the tray 2012.

While the clamps 216 shown in FIGS. 55-58 are modular, a non-modularclamp assembly, such as the spring-loaded clamp assembly 2090 shown inFIG. 59, may be provided. Such a non-modular clamp assembly eliminatesthe need for screws 2050 thus operating to reduce such additionalfailure mechanisms. Accordingly, the spring-loaded clamp assembly 2090includes various spring-loaded clamp components 2092 coupled together bycorresponding body portions 2094. The clamp assembly 2090 is configuredto surround the platform of both a tibial insert and a tibial tray, suchas the tibial insert 2014 and the tibial tray 2012 shown in FIGS. 55-58,and is somewhat flexible to allow the insert to snap into place.

Looking now to FIGS. 60 and 61, another prosthetic knee system includesa tibial insert 2114 (shown in FIG. 60), a fixed tibial tray 2112 (shownin FIG. 60), and a rotating tibial tray 2116 (shown in FIG. 61).Illustratively, the tibial insert 2114 may be used with the fixed tibialtray 2112 to provide a fixed tibial assembly or with the rotating tibialtray 2116 to provide a rotating tibial assembly. The tibial insert 2114includes a platform 2130 having an upper bearing surface 2132 and abottom surface 2134. A stem 2136 is coupled to the bottom surface 2134and a slot 2138 of the platform 2130 is formed within an outerperipheral or side surface 2140 of the platform 2130, as shown in FIG.60. The slot 2138 defines a closed path in the side surface 2140.

The fixed tibial tray 2112 includes a platform 2150, a stem 2152 coupledto a bottom surface 2154 of the platform 2150 and a cavity or bore 2156through the platform 2150 and into the stem 2152 to receive the stem2136 of the tibial insert 2114 therein. The platform 2150 includes abottom wall 2160, a peripheral rim 2162 extending upwardly from thebottom wall 2160, and an inner lip 2164 extending inwardly from aproximal end of the peripheral rim 2162. The bottom wall 2160, rim 2162,and inner lip 2164 cooperate to define a platform-receiving cavity orrecess 2166 of the tibial tray 2112 for receiving at least a portion ofthe platform 2130 of the tibial insert 2114 therein. Illustratively, astem extender 2170 may be coupled to a distal end of the stem 2152 toextend the length of the stem if so desired by the surgeon.

In use, the tibial insert 2114 is snapped into the tibial tray 2112 suchthat the stem 2136 of the insert 2114 is received within the bore 2156of the tray 2112 and the inner lip 2164 of the tray 2112 is receivedwithin the slot 2138 of the insert 2114. Illustratively, the rim 2162and inner lip 2164 of the tray 2112 may be flexible in order to allowthe platform 2130 of the insert 2114 to be snapped into theplatform-receiving cavity 2166 of the tray 2112. Once the tibial insert2114 is coupled to the tray 2112, the tibial insert 2114 is fixedrelative to the tray 2112. In other words, the rim 2162 of the tray 2112operates to prevent the insert 2114 from rotating relative to the tray2112 while the inner lip 2164 of the tray 2112 further operates toprevent lift-off of the insert 2114 relative to the tray 2112 and anymicromotion between the two components.

Looking now to FIG. 61, the rotating tibial tray 2116 simply includes aplatform 2180 and a stem 2182 coupled to a bottom surface 2184 of theplatform 2180. The stem 2136 of the tibial insert 2114 may be receivedwithin the bore 2156 of the tray 2116 such that the bottom surface 2134of the platform 2130 of the insert 2114 is engaged with the top surface2186 of the platform 2180 of the tray 2116. In this configuration, thetibial insert 2114 is able to rotate relative to the tray 2116 toprovide a rotating tibial assembly.

Looking now to FIGS. 62-66, another prosthetic knee system includes atibial tray 2122 (shown in FIGS. 62, 63, 65, and 66), a fixed tibialinsert 2214 (shown in FIGS. 64-66), and a rotating tibial insert (notshown) similar to the rotating tibial insert shown in FIGS. 2, 9, and/or14, for example. Illustratively, the tibial tray 2212 and the fixedtibial insert 2214 cooperate to define a fixed tibial assembly whereinthe tibial insert 2214 is not rotatable relative to the tibial tray2212. Further, the same tibial tray 2212 and the rotating tibial insertcooperate to define a rotating knee assembly wherein the tibial insertis able to rotate relative to the tibial tray 2212.

As shown in FIGS. 62 and 63, the tibial tray 2212 includes a platform2220, a stem 2222 coupled to a bottom surface 2224 of the platform 2220,and a bore 2230 formed through the platform 2220 and into the stem 2222.Illustratively, an opening 2240 formed in the top surface 2242 of theplatform 2220 and in communication with the bore 2230 is shaped toreceive a coordinating hub 2250 (shown in FIG. 64) of the fixed tibialinsert 2214. In particular, the opening 2240 includes two accessopenings 2241. Further, two undercut recesses 2252 formed in theplatform 2220 and the stem 2222 are each communication with the opening2240 and with the bore 2230. The undercut recesses 2252 are eachconfigured to receive a portion of the hub 2250 when the fixed tibialinsert 2214 is in a locked position relative to the tibial tray 2212. Asshown in FIG. 63, the recesses 2252 are each tapered downwardly withinthe bore 2230. Illustratively, the tapered angle 2256 may be between1-89 degrees and is preferably approximately 3 degrees.

Looking now to FIG. 64, the fixed tibial insert 2214 includes a platform2260 having an upper bearing surface 2262 and a bottom surface 2264. Thehub 2250 is coupled to the bottom surface 2264 and configured to bereceived within the opening 2240 and the undercut recesses 2252 of thetibial tray 2212. Illustratively, the hub 2250 includes a center portion2266 and two tabs 2268 extending outwardly therefrom. Furtherillustratively, the shape of the hub 2250 when viewed from the bottom isgenerally the same as the shape of the opening 2240 of the tibial tray2212.

In use, the fixed tibial insert 2214 may be coupled to the tibial tray2212 to define a fixed tibial assembly. Illustratively, the hub 2250 ofthe fixed insert 2214 is received into the opening 2240 of the tray 2212such that the tabs 2268 are received in the access openings 2241. Thefixed tibial insert 2214 is then rotated clockwise toward a lockedposition such that the tabs 2268 of the hub 2250 are received within therespective recesses 2252 of the tibial tray 2212. The taper of theundercut recesses 2252 provides for a snug fit between the tibial insert2214 and the tray 2212. As such, in this locked position, the fixedtibial insert 2214 is not configured to rotate or translate relative tothe tibial tray 2212. Of course, additional locking mechanisms may beused to further fix the tibial insert relative to the tray in order toprevent lift-off, rotation, and/or micromotion as is discussedthroughout this disclosure.

As noted above, a rotating tibial insert such as the tibial insert shownin FIGS. 2, 9, and/or 14, for example, may be provided for use with thetibial tray 2212 such that the rotating tibial insert, when coupled tothe tray 2212, is able to rotate relative to the tray.

Looking now to FIGS. 67 and 68, a fixed knee assembly similar to thefixed knee assembly shown in FIGS. 62-66 is shown. As such, likereference numerals are used to denote like components. The tibial tray2212 shown in FIG. 67 includes recesses 2280 formed in the top surface2242 of the platform 2220. Specifically, two recesses 2280 are providedon either side of the opening 2240.

The fixed tibial insert 2214 includes protrusions 2282 extendingdownwardly from the bottom surface 2264 of the platform 2260.Specifically, two protrusions 2282 are provided on either side of thehub 2250 which correspond to the two recesses 2280 located on eitherside of the opening 2240 of the tray 2212. As such, the protrusions 2282are received within the recesses 2280 when the fixed tibial insert 2214is in the locked position relative to the tibial tray 2212 in order tofurther prevent rotation of the tibial insert 2214 relative to the tray2212 as well as micromotion between the two components. While fourprotrusions 2282 and four recesses 2280 are provided, it is within thescope of this disclosure to provide any number of correspondingprotrusions and recesses on the fixed tibial insert 2214 and the tibialtray 2212.

Looking now to FIGS. 69 and 70, another fixed knee assembly similar tothe fixed knee assembly shown in FIGS. 62-66 is provided. As such, likereference numerals are used to denote like component. As shown in FIG.69, an opening 2290 of the tibial tray 2212 includes four accessopenings 2041 and four corresponding undercut recesses 2252. Further, ahub 2292 of the fixed tibial insert 2214 shown in FIG. 70 includes fourtabs 2268 extending outwardly from the center portion 2266. Similar tothe undercut recesses 2252 discussed above, the undercut recesses 2252shown in FIG. 69 are tapered such that the hub 2292 of the fixed tibialinsert 2214 is inserted into the opening 2290 of the tibial tray 2212and is illustratively rotated counterclockwise such that the tabs 2268of the hub 2292 are each received within a respective undercut recess2252 of the tray 2212 in order to lock the fixed tibial insert 2214 tothe tray 2212.

Looking now to FIGS. 71 and 72, another fixed tibial assembly 2310includes a tibial tray 2312 and a tibial insert 2314 coupled to the tray2312. A locking pin 2316 of the assembly couples the tibial insert 2314to the tray 2312 to prevent rotational movement of the insert 2314relative to the tray 2312. Illustratively, the tibial tray 2312 includesan upwardly-extending flange 2318 coupled to the platform 2320 of thetray 2312. The flange 2318 includes an aperture 2322 formed therethroughwhile an anterior surface 2324 of the insert 2314 includes a bore 2326formed therein. The bore 2326 is illustratively aligned with theaperture 2322 of the flange 2318 when the tibial insert 2314 is receivedon the platform 2320 of the tray 2312. The locking pin 2316 is receivedthrough the aperture 2322 of the tray 2312 and into the bore 2326 of theinsert 2314 in order to prevent rotational movement of the insert 2314relative to the tray 2312. The aperture 2322 and/or the bore 2326 may bethreaded such that a threaded locking pin may be screwed into theaperture 2322 and bore 2326 to more securely retain the pin therein.Although the tibial assembly 2310 is shown and described as a fixedtibial assembly, it should be understood that the tibial insert 2314 maybe able to rotate relative to the tray 2312 with the removal of thelocking pin 2316. In other words, the tibial insert 2314 and the tray2312 may cooperate to provide a rotating tibial assembly as well.

Looking now to FIGS. 73 and 74, another fixed knee assembly 2410 similarto the fixed knee assembly 2314 of FIGS. 71 and 72 is provided. As such,like reference numerals are used to denote like components. The assembly2140 of FIGS. 73 and 74 includes a locking pin 2416 which is generallyhourglass shaped and is configured to be received through a coordinatinghourglass shaped bore 2426 formed in the anterior surface 2324 of thetibial insert 2314. Illustratively, the flange 2418 of the tibial tray2312 includes a generally trapezoidal shaped cutout portion 2420 toreceive the bottom half of the locking pin 2416 therein in order tofixedly coupled the tibial tray 2312 and the tibial insert 2314 togetherto prevent rotation of the tibial insert 2314 relative to the tibialtray 2312. Although the tibial assembly 2410 is shown and described as afixed tibial assembly, it should be understood that the tibial insert2414 may be able to rotate relative to the tray 2412 with the removal ofthe locking pin 2416. In other words, the tibial insert 2414 and thetray 2412 may cooperate to provide a rotating tibial assembly as well.

Looking now to FIGS. 75 and 76, illustrative trays 2512, 2612 eachinclude a keyed recess or opening formed in the platform 2520 of thetray 2512, 2612 in order to receive a coordinating hub of a similarshape extending downwardly from the platform of a fixed tibial insert(not shown) in order to prevent rotational motion of such tibial insertwith respect to the trays 2512, 2612 shown. For example, the keyedopening 2528 of the tibial tray 2512 of FIG. 75 is positioned around thebore 2530 of the tray 2512 and is irregularly shaped. The keyed openingof the tibial tray 2612 shown in FIG. 76, on the other hand, isrectangularly shaped. While such shapes are provided to receive asimilarly-shaped hub of a fixed tibial insert in order to preventrotation of the tibial insert with respect to the tray, it is within thescope of this disclosure for the keyed opening to be provided in anysuitable non-circular shape such as triangle, oval, or square-shaped,for example. Further, while the keyed opening 2528, 2628 of the trays2512, 2612 shown in FIGS. 75 and 76 are located around the bore 2530 ofeach tray 2512, 2612, similar openings may be provided within otherportions of the platform 2518 of each tray 2512, 2612, as is shown inFIGS. 77-83 discussed below.

Looking now to FIGS. 77-83, illustrative trays 2712, 2812, 2912, 3012each include various cutout portions, slots, or bores formed therein.For example, the cutout portions shown in FIG. 77 include four bores2714 formed within the top surface of the tray 2712 while the cutoutportions shown in FIG. 78 include four slots or elongated opening 2814formed within the top surface of the tray 2812. Similarly, the cutoutportions 2914 shown in FIG. 79 include four elongated openinginterconnected with the recessed portions 34, similar to the recessedportions 34 shown in FIGS. 1 and 2) of the tray 2912 while the cutoutportions shown in FIG. 80 include two curved, elongated openings 3014independent from the recessed portions 34 of the tray 3012.

Looking specifically now to FIGS. 81-83, illustrative sectional views ofthe elongated openings 2714, 2814, 2914, 3014 shown in FIGS. 77-80 areprovided. In other words, each of the elongated openings 2714, 2814,2914, 3014 may be formed to define any one of the cross-sectionalprofiles shown in FIGS. 81-83. For example, as shown in FIG. 81, thecross-section of any one of the elongated openings 2714, 2814, 2914,3014 may tapered or trapezoidal in shape while the cross-section of anyone of the cutout portions 2714, 2814, 2914, 3014 may be generally“T-shaped,” as shown in FIG. 82, for example. Finally, the cross-sectionof any one of the cutout portions 2714, 2814, 2914, 3014 may simply berounded, as shown in FIG. 83, and may illustratively be semi-circular.As noted above, a fixed tibial insert (not shown) may includecoordinating tabs of similar shape extending downwardly from the bottomsurface of the platform of such tibial insert. Such protrusions arereceived within the elongated openings in order to prevent rotationalmovement of the tibial insert relative to the particular tibial traywith which it is coupled. Such protrusions further operate to reduce orminimize any micro-motion between the two components.

Looking now to FIGS. 84 and 85, another knee assembly 3110 includes atibial tray 3112 and a tibial insert 3114 coupled to the tray 3112. Alocking pin 3116 of the assembly couples the tibial insert 3114 to thetray 3112 to prevent rotational movement of the insert 3114 relative tothe tray 3112. Illustratively, the tibial tray 3112 includes a bore 3120formed in a top surface 3122 of the platform 3124 of the tray 3112 whilethe tibial insert 3114 includes a through-hole 3128 extending betweenthe upper bearing surface 3130 of the insert 3114 and the bottom surface3132 of the platform 3134 of the insert 3114. Illustratively, thethrough-hole 3128 is positioned anteriorly within the insert 3114, asshown in FIG. 85.

When the tibial insert 3114 is received on the platform 3124 of the tray3112, the hole 3128 of the insert 3114 and the bore 3120 of the tray3112 are aligned. A locking pin 3140 of the assembly 3110 is receivedwithin the hole 3128 and the bore 3120 of the respective tibial tray3114 and insert 3112 in order to prevent rotational movement of thetibial tray 3114 relative to the insert 3112. Although the tibialassembly 3110 is shown and described as a fixed tibial assembly, itshould be understood that the tibial insert 3114 may be able to rotaterelative to the tray 3112 with the removal of the locking pin 3116. Inother words, the tibial insert 3114 and the tray 3112 may cooperate toprovide a rotating tibial assembly as well.

Referring now to FIGS. 89-91, another prosthetic knee system includes atibial tray 4012 (see FIG. 89), a fixed tibial insert 4014 (see FIG.90), and a rotating tibial insert 4016 (see FIG. 91). Looking first toFIG. 89, the tibial tray 4012 includes a platform 4020 and a stem 4022coupled to the bottom surface 4024 of the platform 4020. A cavity 4030is formed through the platform 4020 into the stem 4022. The fixed tibialinsert 4014, shown in FIG. 90, includes a platform 4040 having an upperbearing surface 4041 and a bottom surface 4044. A skirt or rim 4050 ofthe platform 4040 extends around the periphery of the platform 4040 andaway from the bottom surface 4044 of the platform to define atray-receiving area 4052 therein. In use, the rim 4050 of the tibialinsert 4014 surrounds and captures the platform 4020 of the tibial tray4012 within the tray-receiving area 4052 in order to prevent rotation ofthe fixed tibial insert 4014 relative to the tray 4012. The tray 4012may further include a slot or slots, such as slots 4060 formed in a sidesurface 4062 of the platform 4020. The outer rim 4050 of the insert 4014may include tabs 4064 formed on the inner surface 4066 of the rim 4050and extending inwardly into the tray-receiving area 4052. The tabs 4064then operate as a snap feature such that when the non-rotating tibialinsert 4014 is coupled to the tray 4012, the tabs 4064 are receivedwithin the respective slots 4060 in order to further lock the tray 4012and the fixed insert 4014 together. Such a snap feature may also operateto prevent “lift-off” or axial movement of the tibial insert 4014relative to the tray 4012. Further, the snap feature may operate toreduce micro-motion between the tray 4012 and the insert 4014. Suchmicro-motion between the components of a fixed or non-rotating tibialassembly may create wear debris and the snap feature described above mayreduce or prevent such wear debris from forming.

Looking now to FIG. 91, the rotating tibial insert 4016 includes aplatform 4070 and a stem 4072; however, the insert 4016 does not includethe rim 4050 of the fixed tibial insert 4014. As such, when the stem4072 of the rotating tibial insert 4016 is received within the cavity4030 of the tray 4012, the insert 4016 is able to rotate relative to thetray 4012. Accordingly, the rotating tibial insert 4016 and the tray4012 cooperate to provide a rotating tibial assembly.

Illustratively, the outer rim 4050 of the insert 4014 as well as thetabs 4064 of the insert 4014 and the corresponding slots 4060 of thetray 4012 are disclosed within FIGS. 89-91 in order to couple the tibialtray 4012 and the tibial insert 4014 together in order to preventrotation of the tibial insert 4014 relative to the tibial tray 4012, toreduce or minimize micro-motion between the tibial insert and the tibialtray, and/or to prevent lift-off of the tibial insert relative to thetibial tray, for example. It is within the scope of this disclosure,however, to include other locking features located on or within thetibial insert 4014 and/or tibial tray 4012 to prevent relative movementbetween the tibial insert 4014 and the tibial tray 4012. It is alsowithin the scope of this disclosure to include locking features whichare embodied by components separate from the tibial insert 4014 and thetibial tray 4012 disclosed herein and which may be coupled to one ormore of the tibial insert 4014 and the tibial tray 4012 in order toprevent relative movement therebetween.

Referring now to FIGS. 92-95, in another embodiment, a prosthetic kneesystem 4100 includes a tibial tray 4102, a fixed or non-rotating tibialinsert 4104 (see FIGS. 92 and 93) and a rotating tibial insert 4106 (seeFIGS. 94 and 95). The tibial inserts 4104, 4106 are illustrativelyformed from a polymer material, but may be formed from other materials,such as a ceramic material, a metallic material, a bio-engineeredmaterial, or the like, in other embodiments. Similarly, the tibial tray4102 is illustratively formed from a metallic material, but may beformed from other materials, such as a ceramic material, a polymermaterial, a bio-engineered material, or the like, in other embodiments.

The tibial tray 4102 includes a platform 4108 and a stem 4110. Theplatform 4108 includes an upper surface 4112, a bottom surface 4114, anda side surface 4116 extending between the upper surface 4112 and thebottom surface 4114. The stem 4110 extends downwardly from the bottomsurface 4114 of the platform 4108. The platform 4108 includes a slot4118 defined in the side surface 4116. Illustratively, the slot 4118 isdefined along the length of the side surface 4116 and defines a closedpath. However, in other embodiments, the slot 4118 may be embodied as aslot defining an open path, be defined only on particular sections ofthe side surface 4116, and/or be embodied as a number of smaller slots.The platform 4108 also includes a post 4120 extending upwardly from theupper surface 4112. The post 4120 includes a flange 4122 defined at aproximal end 4124. Illustratively, the flange 4122 includes a upwardlynarrowing taper, but flanges having other configurations may be used inother embodiments.

In use, the tibial tray 4102 is configured to be coupled to asurgically-prepared surface of the proximal end of a patient's tibia(not shown). When the tibial tray 4102 is so coupled, the stem 4110 isembedded in patient's tibia to thereby secure the tibial tray 4102 tothe patient's bone. In some embodiments, a stem extension (not shown)may include coupled to the stem 4110 to increase the overall length ofthe stem 4110 and improve the stability of the tibial tray relative tothe patient's bony anatomy.

The tibial insert 4104 includes an upper bearing surface 4126 and abottom surface 4128. The upper bearing surface 4126 is configured tocontact a pair of natural or prosthetic femoral condyles of the patient.The bottom surface 4128 includes an aperture 4130 defined therein. Asdiscussed below, the aperture 4130 is configured to receive the post4120 defined on the upper surface 4112 of the platform 4108 of thetibial tray 4102. The tibial insert 4104 also includes a skirt or rim4132 extending downwardly from the bottom surface 4128. The rim 4132includes a number of tabs 4144 extending inwardly. Illustratively, therim 4132 includes a number of individual downwardly extending sections.Each section includes a separate inwardly extending tab 4132.

As illustrated in FIG. 93, the tibial insert 4104 is configured to becoupled to the tibial tray 4102 in use. To do so, the tibial insert 4104is positioned on the upper surface 4112 of the platform 4108 such thatthe post 4120 is received in the aperture 4130 defined in the bottomsurface 4116 of the tibial insert 4104. Additionally, the tabs 4144 arereceived in the slot 4118 defined in the side surface 4116 of theplatform 4108 of the tibial tray 4102. When so coupled, the bottomsurface 4128 of the tibial insert 4104 is in contact with the uppersurface 4112 of the platform 4108 of the tibial tray 4102. In addition,when the non-rotating tibial insert 4104 is coupled to the tibia tray4102 as shown in FIG. 93, the rim 4132 surrounds the side surface 4116of the platform 4108 of the tibial tray 4102. The slot 4118 of thetibial tray 4102 and the rim 4132 and tabs 4144 of the rotating tibialinsert 4104 cooperate to restrict or prevent rotation of the tibialinsert 4104 relative to the tibial tray 4102, to reduce micro-motionbetween the tibial insert 4104 and the tibial tray 4102, and/or toprevent lift-off of the tibial insert 4104 relative to the tibial tray4102.

As shown in FIG. 94-95, the rotating tibial insert 4104 may be used withthe tibial tray 4102 in place of the non-rotating tibial insert 4104. Insome embodiments, the rotating tibial insert 4106 is separate from therotating tibial insert 4104 and includes an upper bearing surface 4150,a bottom surface 4152, an aperture 4154 defined in the bottom surface4150 similar to the upper bearing surface 4126, the bottom surface 4128,and the aperture 4130 of the non-rotating tibial insert 4104. However,in other embodiments, the rim 4132 of the non-rotating tibial insert4104 is configured to be removed therefrom to selectively change thenon-rotating tibial insert 4104 into a rotating tibial insert. It shouldbe appreciated that, in such embodiments, the non-rotating tibial insert4104 and the rotating tibial insert 4106 are the same tibial insert.Additionally, in such embodiments, the tibial insert 4104, 4106 mayinclude a slot 4160 (see FIG. 94) defined in a side wall 4162 configuredto receive a portion of the rim 4132 to secure the rim 4132 to thetibial insert 4104, 4106.

As shown in FIG. 95, the rotating tibial insert 4106 may be coupled tothe tibial tray 4102 in a manner similar to the non-rotating tibialinsert 4104. To do so, the rotating tibial insert 4106 is positioned onthe upper surface 4112 of the platform 4108 such that the post 4120 isreceived in the aperture 4154 defined in the bottom surface 4152 of thetibial insert 4106. When so coupled, the bottom surface 4152 of thetibial insert 4106 is in contact with the upper surface 4112 of theplatform 4108 of the tibial tray 4102. Because the rotating tibialinsert 4106 does not include the rim 4132 and tabs 4114, the insert isfree to rotate about an axis 4156 defined by the post 4120 of the tibialinsert 4102. In should be appreciated that the circular shape of thepost 4120 facilitates the rotation of the rotating tibial insert 4106.

Referring now to FIG. 96, in another embodiment, a prosthetic kneesystem 4200 includes a tibial tray 4202, a fixed or non-rotating tibialinsert 4204, and a rotating tibial insert (not shown). The rotatingtibial insert may be similar to the rotating tibial insert 794 describedabove in regard to FIG. 87. The tibial insert 4204 is illustrativelyformed from a polymer material, but may be formed from other materials,such as a ceramic material, a metallic material, a bio-engineeredmaterial, or the like, in other embodiments. Similarly, the tibial tray4202 is illustratively formed from a metallic material, but may beformed from other materials, such as a ceramic material, a polymermaterial, a bio-engineered material, or the like, in other embodiments.

The tibial tray 4202 includes a platform 4206 and a stem 4208. Theplatform includes an upper surface 4210, a bottom surface 4212, and aside surface 4214 extending between the upper surface 4210 and thebottom surface 4212. The tibial tray 4202 also includes a cavity 4216having an opening 4218 defined on the upper surface 4210. The stem 4208extends downwardly from the bottom surface 4212 of the platform 4206.The platform 4206 includes a number of slots 4220 defined in the sidesurface 4214. Illustratively, the platform 4206 includes a slot 4220defined in the lateral side of the side surface 4214, a slot 4220defined in the anterior side of the side surface 4214, and a slot 4220defined in the medial side of the side surface 4220. However, in otherembodiments, the platform 4206 may include any number of slots 4220defined in the side surface 4214.

As described above in regard to the tibial tray 4102 of FIGS. 92-95, thetibial tray 4202 is configured to be coupled to a surgically-preparedsurface of the proximal end of a patient's tibia (not shown). When thetibial tray 4202 is so coupled, the stem 4208 is embedded in patient'stibia to thereby secure the tibial tray 4202 to the patient's bone. Insome embodiments, a stem extension (not shown) may include coupled tothe stem 4208 to increase the overall length of the stem 4208 andimprove the stability of the tibial tray 4202 relative to the patient'sbony anatomy.

The tibial insert 4204 includes an upper bearing surface 4222, a bottomsurface 4224, and a stem 4226. The upper bearing surface 4222 isconfigured to contact a pair of natural or prosthetic femoral condylesof the patient. The stem 4226 extends downwardly from the bottom surface4224. The tibial insert 4204 also includes a sectioned rim 4228extending downwardly from the bottom surface 4224. The rim 4228 includesa number of tabs 4230 extending inwardly. Illustratively, the rim 4228includes a lateral rim section 4232, an anterior rim section 4234, and amedial rim section 4336. Each section 4232, 4334, 4336 includes aseparate inwardly extending tab 4230. However, in other embodiments, therim 4228 may include more or less sections.

The tibial insert 4204 is configured to be coupled to the tibial tray4202 in use. To do so, the tibial insert 4204 is positioned such thatthe stem 4206 is received in the opening 4218 defined in the uppersurface 4210 of the tibial tray 4202. The tibial insert 4204 is seatedon the upper surface 4210 of the platform 4206 such that the of the tabs4230 of the rim 4228 are received in the corresponding slots 4220defined in the side surface 4214 of the platform 4206 of the tibial tray4202. When so coupled, the bottom surface 4224 of the tibial insert 4204is in contact with the upper surface 4210 of the platform 4206 of thetibial tray 4202. The slots 4220 of the tibial tray 4202 and the rim4228 and tabs 4230 of the rotating tibial insert 4204 cooperate torestrict or prevent rotation of the tibial insert 4204 relative to thetibial tray 4202, to reduce micro-motion between the tibial insert 4204and the tibial tray 4202, and/or to prevent lift-off of the tibialinsert 4204 relative to the tibial tray 4202.

A rotating tibial insert, similar to the tibial insert 794, may be usedwith the tibial tray in place of the non-rotating tibial insert. Therotating tibial insert may be coupled to the tibial tray in a mannersimilar to the non-rotating tibial insert. To do so, the rotating tibialinsert is positioned such that a stem of the rotating tibial insert isreceived in the opening defined in the upper surface of the tibial tray.Because the rotating tibial insert does not include the tabs of thenon-rotating tibial insert, the insert is free to rotate about an axisdefined by the post of the tibial insert.

Referring now to FIGS. 97-99, in another embodiment, a prosthetic kneesystem 4300 includes a tibial tray 4302, a fixed or non-rotating tibialinsert 4304, and a rotating tibial insert (not shown). The rotatingtibial insert 4304 may be similar to the rotating tibial insert 794described above in regard to FIG. 87. The tibial insert 4304 isillustratively formed from a polymer material, but may be formed fromother materials, such as a ceramic material, a metallic material, abio-engineered material, or the like, in other embodiments. Similarly,the tibial tray 4302 is illustratively formed from a metallic material,but may be formed from other materials, such as a ceramic material, apolymer material, a bio-engineered material, or the like, in otherembodiments.

The tibial tray 4302 includes a platform 4306 and a stem 4308. Theplatform 4306 includes an upper surface 4310, a bottom surface 4312, anda side surface 4314 extending between the upper surface 4310 and thebottom surface 4312. The stem 4308 extends downwardly from the bottomsurface 4812 of the platform 4306. The tibial tray 4302 also includes acavity 4316 having a keyed opening 4318 defined on the upper surface4310. Illustratively, as shown in FIG. 97, the keyed opening hascruciform shape (i.e., the keyed opening 4318 has a cruciform topprofile). However, as discussed in more detail below, the keyed opening4318 may have other shapes in other embodiments. The cavity 4316 isdefined by an inner wall 4320 of the tibial tray and has an inwardlysloping taper as discussed in more detail below.

As described above in regard to the tibial tray 4102 of FIGS. 92-95, thetibial tray 4302 is configured to be coupled to a surgically-preparedsurface of the proximal end of a patient's tibia (not shown). When thetibial tray 4302 is so coupled, the stem 4308 is embedded in patient'stibia to thereby secure the tibial tray 4302 to the patient's bone. Insome embodiments, a stem extension (not shown) may include coupled tothe stem 4308 to increase the overall length of the stem 4308 andimprove the stability of the tibial tray 4302 relative to the patient'sbony anatomy.

The tibial insert 4304 includes an upper bearing surface 4322, a bottomsurface 4324, and a stem 4326. The upper bearing surface 4322 isconfigured to contact a pair of natural or prosthetic femoral condylesof the patient. The stem 4326 extends downwardly from the bottom surface4324 and includes a base 4328 and an elongated shaft 4330 extendingdownwardly from the base 4328. The base 4328 of the stem 4326 has ashape corresponding to the shape of the keyed opening 4318 of the tibialtray 4302. For example, in the illustrative embodiments of FIG. 97, thebase 4328 of the stem 4326 has a cruciform shape such that the base 4328is configured to be received in the keyed opening 4318 when the tibialinsert 4304 is coupled to the tibial tray 4302. Although the keyedopening 4318 and base 4328 have a cruciform shape in the illustrativeembodiments, the keyed opening 4318 and base 4328 may have othercorresponding non-circular shapes in other embodiments. For example, thekeyed opening 4318 and base 4328 may have octagonal or star shape asillustrated in FIG. 75 or a rectangular or square shape as illustratedin FIG. 76.

The non-rotating tibial insert 4304 also includes a metal ring 4332secured to a central portion of the shaft 4330 of the stem 4326. Themetal ring 4322 has an inwardly sloping taper that corresponds to thetaper of the inner sidewall 4320 of the tibial tray 4302. The tapers ofthe metal ring 4332 and the inner sidewall 4320 are designed such thatwhen the non-rotating tibial insert 4304 is coupled to the tibial tray4302, the metal ring 4332 and the inner sidewall 4320 contact each otherand form a friction lock therebetween as illustrated in FIG. 99. In oneparticular embodiment, the tapers of the metal ring 4332 and the innersidewall 4320 are embodied as corresponding Morse tapers. For example,in one particular embodiment, a Morse taper having a taper-per-foot inthe range of about 0.59858 to about 0.63151 may be used. However, inother embodiments, other types of friction lock tapers may be used.

In some embodiments, the non-rotating tibial insert 4304 may alsoinclude a rim or skirt 4434 extending downwardly from the bottom surface4324 of the tibial insert 4304. The rim 4334 includes a tab 4336extending inwardly therefrom. The rim 4334 may extend downwardly fromthe periphery of the bottom surface 4324 or from only a portion thereofas illustrated in FIG. 97. Illustratively, the rim 4334 and/or the tabis formed from a flexible material. The flexible material may beembodied as any material flexible enough to allow the tibial insert 4304to be coupled to the tibial tray 4302, but rigid enough to provide someamount of resistance to lift-off as described below.

The tibial insert 4304 is configured to be coupled to the tibial tray4302 in use. To do so, the tibial insert 4304 is positioned such thatthe elongated shaft 4330 of the stem 4326 is received in the cavity 4366of the tibial tray 4302 and the base 4328 of the stem 4326 is receivedin the keyed opening 4318. In embodiments wherein the tibial insert 4304includes the rim 4334, the tibial insert 4304 is seated on the uppersurface 4310 of the platform 4306 such that the tabs 4336 of the rim4334 clip the bottom surface 4312 of the tibial tray 4302 as illustratedin FIG. 99. In some embodiments, the orthopaedic prosthesis assembly4330 may also include a fastener 4340, which may be embodied as a screwor bolt. In such embodiments, the tibial insert 4304 includes aninternal passageway 4342 extending therethrough. The passageway 4342includes an opening 4344 in the upper bearing surface 4322. The cavity4320 of the tibial tray 4302 includes a threaded aperture 4346 definedat a distal end of the cavity 4320. Once the non-rotating tibial insert4304 is coupled to the tibial tray 4302, the fastener 4340 may beinserted into the internal passageway 4342 of the tibial insert 4304 andthreaded into the threaded aperture 4346 of the tibial tray 4302 tothereby secure the tibial insert 4304 to the tibial tray 4302 asillustrated in FIG. 99.

When the non-rotating tibial insert 4304 is coupled to the tibial tray4302, the bottom surface 4324 of the tibial insert 4304 is in contactwith the upper surface 4310 of the platform 4306 of the tibial tray4302. In addition, the base 4328 of the stem 4326 is received in thekeyed opening 4318 of the tibial tray 4302 and the tab 4336 of thetibial insert 4304 is clipped over the bottom surface 4312 of the tibialtray 4302. Additionally, as discussed above, the metal ring 4332 securedto the stem 4326 of the tibial insert 4304 is in contact with the innersidewall 4320 of the tibial tray 4302 to form a friction locktherebetween. The friction lock, rim 4334, and fastener 4340 (if used)cooperate to restrict or prevent rotation of the tibial insert 4304relative to the tibial tray 4302, to reduce micro-motion between thetibial insert 4304 and the tibial tray 4302, and/or to prevent lift-offof the tibial insert 4304 relative to the tibial tray 4302.

A rotating tibial insert, similar to the tibial insert 794, may be usedwith the tibial tray 4302 in place of the non-rotating tibial insert4304. The rotating tibial insert may be coupled to the tibial tray 4302in a manner similar to the non-rotating tibial insert 4304. To do so,the rotating tibial insert is positioned such that a stem of therotating tibial insert is received in the cavity 4320 defined in theupper surface of the tibial tray 4302. Because the rotating tibialinsert does not include the keyed base 4328 of the non-rotating tibialinsert 4304, the insert is free to rotate about an axis 4328 of the postof the tibial insert 4302.

Referring now to FIGS. 100-102, in another embodiment, a prosthetic kneesystem 4400 includes a tibial tray 4402, a fixed or non-rotating tibialinsert 4404 (see FIGS. 100 and 101), and a rotating tibial insert 4406(see, e.g., FIG. 102). The tibial inserts 4402, 4004 are illustrativelyformed from a polymer material, but may be formed from other materials,such as a ceramic material, a metallic material, a bio-engineeredmaterial, or the like, in other embodiments. Similarly, the tibial trayis illustratively formed from a metallic material, but may be formedfrom other materials, such as a ceramic material, a polymer material, abio-engineered material, or the like, in other embodiments.

The tibial tray 4402 includes a platform 4408 and a stem 4410. Theplatform 4408 includes an upper surface 4412, a bottom surface 4414, anda side surface 4416 extending between the upper surface 4412 and thebottom surface 4414. The tibial tray 4402 also includes a cavity 4418having an opening 4420 defined on the upper surface 4412. The stem 4410extends downwardly from the bottom surface 4414 of the platform 4408.The platform 4408 includes a medial guide track 4422 and a lateral guidetrack 4424 defined in the upper surface 4412. It should be appreciatedthat although the guide tracks 4422, 4424 are referred to as medial andlateral guide tracks, respectively, the particular orientation of eachtrack 4422, 4424 depends upon which knee of the patient is receiving theorthopaedic prosthesis. As such, either guide track 4422, 4424 may be amedial or lateral track. Regardless, for clarity, the guide track willbe refereed to as a medial guide track 4422 and the guide track will bereferred to as a lateral guide track 4424 with the understanding thateither guide track may be a medial/lateral guide track based on theparticular application.

Illustratively, the guide tracks 4422, 4424 are defined in the uppersurface 4412 of the tibial tray 4402 in the anterior/posteriordirection. However, in other embodiments, the guide tracks 4422, 4424may be defined in the upper surface 4412 in other directions.Additionally, although the illustrative embodiment includes only twoguide tracks 4422, 4424, the tibial tray 4402 may include additionalguide tracks in other embodiments. Illustratively, each guide track4422, 4424 is defined by a first sidewall 4426, a second sidewall 4428,and a bottom wall 4430. The first and second sidewalls 4426, 4428 aretapered inwardly such that the guide tracks 4422, 4424 have asubstantially dovetail shape. That is, each of the guide tracks 4422,4424 has a dovetail shaped cross-section. However, in other embodiments,the guide tracks 4422, 4424 may have other shapes. For example, in someembodiments, the first and second sidewalls 4426, 4428 may besubstantially straight such that the guide tracks 4422, 4424 have asubstantially rectangular or square shape. Alternatively, as illustratedin FIG. 101, the guide tracks 4422, 4424 may include straight side walls4432, 4434 having a first lip 4436 and second lip 4438 extendinginwardly therefrom. The lips 4436, 4438 define an opening 4430therebetween. In such embodiments, the guide tracks 4422, 4424 aresubstantially “T”-shaped. Additionally, in some embodiments, the medialguide track 4422 may have a shape different from the lateral guide track4424. For example, as illustrated in FIG. 102, the medial guide track4422 may have a substantially dovetail shape while the lateral guidetrack 4424 has a substantially “T” shape. Such a configuration allowsthe non-rotating tibial insert 4404 to be keyed as discussed below suchthat the tibial insert 4404 may be coupled to the tibial tray 4402 inonly a single orientation.

Again, as described above in regard to the tibial tray 4102 of FIGS.92-95, the tibial tray 4402 is configured to be coupled to asurgically-prepared surface of the proximal end of a patient's tibia(not shown). When the tibial tray 4402 is so coupled, the stem 4410 isembedded in patient's tibia to thereby secure the tibial tray 4402 tothe patient's bone. In some embodiments, a stem extension (not shown)may include coupled to the stem 4410 to increase the overall length ofthe stem 4410 and improve the stability of the tibial tray 4402 relativeto the patient's bony anatomy.

The tibial insert 4404 includes an upper bearing surface 4444, a bottomsurface 4446, and a pair of rails 4448, 4450. The upper bearing surfaceis 4444 configured to contact a pair of natural or prosthetic femoralcondyles of the patient. The tibial insert 4404 includes an internalpassageway 4452 having an opening 4454 defined in the upper bearingsurface 4444. The rails 4448, 4450 extend downwardly from the bottomsurface 4446 and are positioned thereon in an orientation and locationcorresponding to the guide tracks 4422, 4424 of the tibial insert 4404such that the tibial insert 4404 may be coupled thereto. For example, inthe illustrative embodiment, the rails 4448, 4450 extend across thebottom surface 4446 in an anterior/posterior direction. Additionally,the rails 4448, 4450 have a shape corresponding to the shape of theguide tracks 4422, 4424 such that the rails 4448, 4450 may be receivedtherein. In the embodiment illustrated in FIG. 100, the rails 4448, 4450have a substantially dovetail shape. However, in the embodimentillustrated in FIG. 101, the rails 4448, 4450 have substantially“T”-shape and may have other shapes in other embodiments.

The orthopaedic prosthesis assembly 4400 also includes a stem 4460separate from the tibial insert 4404 and the tibial tray 4402 and afastener 4462 such as a screw or bolt. The stem 4460 is insertable intothe internal passageway 4452 of the tibial insert 4404 and the cavity4418 of the tibial tray 4402 via the respective openings 4454, 4420. Todo so, the tibial insert 4404 is positioned such that each rail 4448,4450 is received in the corresponding guide track 4422, 4424. The tibialinsert 4404 is then moved to a location in which the opening 4420defined in the upper surface 4412 of the tibial tray 4402 is in registrywith the internal passageway 4452 defined in the tibial insert 4404. Thestem 4460 is then inserted into the passageway 4452. A portion of thestem 4460 also extends into the cavity 4418 of the tibial tray 4402. Thestem 4460 includes an internal passageway 4464 sized to receive thefastener 4462, which is threaded into a threaded aperture (not shown)defined at the distal end of the cavity 4418 of the tibial tray 4402 tosecure the tibial insert 4404 to the tibial tray 4402.

When the non-rotating tibial insert 4404 is coupled to the tibial tray4402, the bottom surface 4406 of the tibial insert 4404 is in contactwith the upper surface 4412 of the platform 4408 of the tibial tray4402. In addition, each rail 4448, 4450 is received in the correspondingguide track 4422, 4424. The rails 4448, 4450, guide tracks 4422, 4424,and stem 4460 cooperate to restrict or prevent rotation of the tibialinsert 4404 relative to the tibial tray 4402, to reduce micro-motionbetween the tibial insert 4404 and the tibial tray 4402, and/or toprevent lift-off of the tibial insert 4404 relative to the tibial tray4402.

As shown in FIG. 102, rotating tibial insert 4406 may be used with thetibial tray 4402 in place of the non-rotating tibial insert 4404. Therotating tibial insert 4406 is similar to the tibial insert 794 andincludes a platform 4470 having an upper bearing surface 4472 and bottomsurface 4474 and a stem 4476 extending from the bottom surface 4474. Therotating tibial insert 4406 may be coupled to tibial tray 4402 bypositioning the rotating tibial insert 4406 such that a stem 4476 of therotating tibial insert 4406 is received in the cavity 4418 defined inthe upper surface 4412 of the tibial tray 4402. Because the rotatingtibial insert 4406 does not include rails extending from the bottomsurface 4472, the insert 4406 is free to rotate about an axis relativeto the tibial tray 4402.

In some embodiments, the rails 4448, 4450 may be removable from thetibial insert 4404. For example, the rails 4448, 4450 may be secured tothe to the tibial insert 4404 via a number of removable securing devicessuch as bolts or the like. In such embodiments, the rails 4448, 4450 maybe removed from the tibial insert 4404 by removing the securing devices.In other embodiments, the tibial insert 4404 may include a pair of guidetracks similar to the guide tracks 4422, 4424 of the tibial tray 4402.In such embodiments, the rails 4448, 4450 are separate from the tibialinsert 4404. Additionally, in such embodiments, the rails 4448, 4450 areconfigured to be received in the guide tracks of the tibial insert 4404and into the guide tracks 4422, 4424 of the tibial tray. For example,the rails 4448, 4450 may be substantially “I”-shaped. Regardless, inembodiments wherein the rails 4448, 4450 are removable from the tibialinsert 4404 and/or the tibial tray 4402, the tibial insert 4404 may beconfigurable as a fixed or a mobile bearing. That is, when the rails4448, 4450 are coupled to the tibial insert 4404 and/or the tibial tray4402, the tibial insert 4404 is configured as a fixed bearing. However,when the rails 4448, 4450 are removed from the tibial insert 4404 and/orthe tibial tray 4402, the tibial insert 4404 is configured as a mobilebearing.

Referring now to FIGS. 103-106, in another embodiment, a prosthetic kneesystem 4500 includes a tibial tray 4502, a fixed or non-rotating tibialinsert 4504, and a rotating tibial insert (not shown). The rotatingtibial insert may be similar to the rotating tibial insert 794 describedabove in regard to FIG. 87. The non-rotating tibial insert 4504 isillustratively formed from a polymer material, but may be formed fromother materials, such as a ceramic material, a metallic material, abio-engineered material, or the like, in other embodiments. Similarly,the tibial tray 4502 is illustratively formed from a metallic material,but may be formed from other materials, such as a ceramic material, apolymer material, a bio-engineered material, or the like, in otherembodiments.

The tibial tray 4502 includes a platform 4506 and a stem 4508. Theplatform 4506 includes an upper surface 4510, a bottom surface 4512, anda side surface 4514 extending between the upper surface 4510 and thebottom surface 4512. The stem 4508 extends downwardly from the bottomsurface 4512 of the platform 4506. The tibial tray 4502 also includes acavity 4516 having an opening 4518 defined on the upper surface 4510.The cavity 4516 is defined by an inner sidewall 4520 having an inwardlysloping taper. The platform 4506 includes a slot 4522 defined in theside surface 4514. Illustratively, the slot 4522 is defined along thelength of the side surface 4514 and defines a closed path. However, inother embodiments, the slot 4522 may be embodied as a slot defining anopen path, be defined only on particular sections of the side surface4514, and/or be embodied as a number of smaller slots.

The tibial tray 4502 is configured to be coupled to asurgically-prepared surface of the proximal end of a patient's tibia(not shown). When the tibial tray 4502 is so coupled, the stem 4508 isembedded in patient's tibia to thereby secure the tibial tray 4502 tothe patient's bone. In some embodiments, a stem extension (not shown)may include coupled to the stem 4508 to increase the overall length ofthe stem 4508 and improve the stability of the tibial tray 4502 relativeto the patient's bony anatomy.

The tibial insert 4504 includes an upper bearing surface 4524, a bottomsurface 4526, and a stem 4528. The upper bearing surface 4524 isconfigured to contact a pair of natural or prosthetic femoral condylesof the patient. The stem 4528 extends downwardly from the bottom surface4526 and includes a metal ring 4530 secured thereto. The metal ring 4530has an inwardly sloping taper that corresponds to the taper of an innersidewall 4520 of the tibial tray 4502. The tapers of the metal ring 4530and the inner sidewall 4520 are designed such that when the non-rotatingtibial insert 4504 is coupled to the tibial tray 4502, the metal ring4530 and the inner sidewall 4520 contact each other and form a frictionlock therebetween. In one particular embodiment, the tapers of the metalring 4530 and the inner sidewall 4520 are embodied as correspondingMorse tapers. For example, in one particular embodiment, a Morse taperhaving a taper-per-foot in the range of about 0.59858 to about 0.63151may be used. However, in other embodiments, other types of friction locktapers may be used.

The non-rotating tibial insert 4504 also includes a rim or skirt 4532extending downwardly form the bottom surface 4526 of the tibial insert4504. The rim 4532 includes a tab 4534 extending inwardly therefrom. Therim 4532 may extend downwardly from the complete periphery of the bottomsurface 4526 or from only a portion thereof. Illustratively, the rim4532 and/or the tab 4534 is formed from a flexible material. Theflexible material may be embodied as any material flexible enough toallow the tibial insert 4504 to be coupled to the tibial tray 4502, butrigid enough to provide some amount of resistance to lift-off asdescribed below.

The tibial insert 4504 is configured to be coupled to the tibial tray4502 in use. To do so, the tibial insert 4504 is positioned such thatthe stem 4528 is received in the cavity 4516 of the tibial tray 4502.The tibial insert 4504 is seated on the upper surface 4510 of theplatform 4506 such that the tab 4534 of the rim 4532 is received in theslot 4522 defined on the side surface 4514 of the tibial tray 4502. Whennon-rotating tibial insert 4504 is coupled to the tibial tray 4502, thebottom surface 4526 of the tibial insert 4504 is in contact with theupper surface 4510 of the platform 4506 of the tibial tray 4502. Inaddition, the metal ring 4530 secured to the stem 4528 of the tibialinsert 4504 is in contact with the inner sidewall 4520 of the tibialtray 4502 to form a friction lock therebetween. The friction lock, rim4534, and slot 4522 cooperate to restrict or prevent rotation of thetibial insert 4504 relative to the tibial tray 4502, to reducemicro-motion between the tibial insert 4504 and the tibial tray 4502,and/or to prevent lift-off of the tibial insert 4504 relative to thetibial tray 4502.

A rotating tibial insert, similar to the tibial insert 794, may be usedwith the tibial tray 4502 in place of the non-rotating tibial insert4504. The rotating tibial insert may be coupled to the tibial tray 4502in a manner similar to the non-rotating tibial insert 4504. To do so,the rotating tibial insert is positioned such that a stem of therotating tibial insert is received in the cavity 4516 of the tibial tray4504. Because the rotating tibial insert does not include the metal ring4530 and rim 4532 of the non-rotating tibial insert 4504, the rotatingtibial insert is free to rotate about an axis defined by the stem of therotating tibial insert.

Referring now to FIGS. 104-106, in another embodiment, a prosthetic kneesystem 4600 includes a tibial tray 4602, a fixed or non-rotating tibialinsert 4604, and a rotating tibial insert (not shown). The rotatingtibial insert may be similar to the rotating tibial insert 794 describedabove in regard to FIG. 87. The non-rotating tibial insert 4604 isillustratively formed from a polymer material, but may be formed fromother materials, such as a ceramic material, a metallic material, abio-engineered material, or the like, in other embodiments. Similarly,the tibial tray 4602 is illustratively formed from a metallic material,but may be formed from other materials, such as a ceramic material, apolymer material, a bio-engineered material, or the like, in otherembodiments.

The tibial tray 4602 includes a platform 4606 and a stem 4608. Theplatform 4606 includes an upper surface 4610, a bottom surface 4612, anda side surface 4614 extending between the upper surface 4610 and thebottom surface 4612. The side surface 414 has an outwardly slopingtaper. The stem 4608 extends downwardly from the bottom surface 4612 ofthe platform 4606. The tibial tray 4602 also includes a cavity 4616having an opening 4618 defined in the upper surface 4610. The cavity4616 is defined by an inner sidewall 4620 having an inwardly slopingtaper. In some embodiments, such as the embodiment illustrated in FIG.106, the platform 4606 may include a slot 4622 defined in the sidesurface 4614. In such embodiments, the slot 4622 may be defined alongthe length of the side surface 4614 and may define a closed path.However, in other embodiments, the slot 4622 may be embodied as a slotdefining an open path, be defined only on particular sections of theside surface 4614, and/or be embodied as a number of smaller slots.

Again, as discussed with previous embodiments, the tibial tray 4602 isconfigured to be coupled to a surgically-prepared surface of theproximal end of a patient's tibia (not shown). When the tibial tray 4602is so coupled, the stem 4608 is embedded in patient's tibia to therebysecure the tibial tray 4602 to the patient's bone. In some embodiments,a stem extension (not shown) may include coupled to the stem 4608 toincrease the overall length of the stem 4608 and improve the stabilityof the tibial tray 4602 relative to the patient's bony anatomy.

The tibial insert 4604 includes an upper bearing surface 4624, a bottomsurface 4626, and a stem 4628. The upper bearing surface 4624 isconfigured to contact a pair of natural or prosthetic femoral condylesof the patient. The stem 4628 extends downwardly from the bottom surface4626 and includes a metal ring 4630 secured thereto. The metal ring 4630has an inwardly sloping taper that corresponds to the taper of the innersidewall 4620 of the tibial tray 4602. The tapers of the metal ring 4630and the inner sidewall 4620 are designed such that when the non-rotatingtibial insert 4604 is coupled to the tibial tray 4602, the metal ring4630 and the inner sidewall 4620 contact each other and form a frictionlock therebetween. In one particular embodiment, the tapers of the metalring 4630 and the inner sidewall 4620 are embodied as correspondingMorse tapers. For example, in one particular embodiment, a Morse taperhaving a taper-per-foot in the range of about 0.59858 to about 0.63151may be used. However, in other embodiments, other types of friction locktapers may be used.

The non-rotating tibial insert 4604 also includes a rim or skirt 4632extending downwardly from the bottom surface 4626 of the tibial insert4604. The rim 4632 has an outwardly sloping taper that corresponds tothe taper of the sidewall 4614 of the platform 4604 of the tibial tray4602. The tapers of the rim 4632 and the sidewall 4614 are designed suchthat when the non-rotating tibial insert 4604 is coupled to the tibialtray 4602, the rim 4632 and sidewall 4614 contact each other and form afriction lock therebetween. In one particular embodiment, the tapers ofthe rim 4632 and the sidewall 4614 are embodied as corresponding Morsetapers. For example, in one particular embodiment, a Morse taper havinga taper-per-foot in the range of about 0.59858 to about 0.63151 may beused. However, in other embodiments, other types of friction lock tapersmay be used. Additionally, in embodiments wherein the sidewall 4614 ofthe platform 4606 includes the slot 4622, the rim 4632 may include a tab4640 extending inwardly therefrom as illustrated in FIG. 106. The tab4640 may define a closed path in some embodiments. Alternatively, thetab 4640 may be formed from a number of sections defined along theinside surface of the rim 4632.

The non-rotating tibial insert 4604 is configured to be coupled to thetibial tray 4602 in use. To do so, the tibial insert 4604 is positionedsuch that the stem 4628 is received in the cavity 4616 of the tibialtray 4602 and the rim 4632 encircles and contacts the side surface 4614of the platform 4606 of the tibial insert 4604. As illustrated in FIGS.105 and 106, the orthopaedic prosthesis assembly 4600 may also include afastener 4642 in some embodiments. The fastener 4642 may be embodied asa screw or bolt. In such embodiments, the tibial insert 4604 includes aninternal passageway 4644 extending therethrough. The passageway 4644includes an opening 4646 in the upper bearing surface 4624. The cavity4616 of the tibial insert 4604 includes a threaded aperture 4648 definedat a distal end of the cavity 4616. Once the non-rotating tibial insert4604 is coupled to the tibial tray 4602, the fastener 4642 may beinserted into the internal passageway 4644 of the tibial insert 4604 andthreaded into the threaded aperture 4648 of the tibial tray 4602 tothereby secure the tibial insert 4604 to the tibial tray 4602.

When the non-rotating tibial insert 4604 is coupled to the tibial tray4602, the bottom surface 4626 of the tibial insert 4604 is in contactwith the upper surface 4610 of the platform 4606 of the tibial tray4602. In addition, the stem 4628 is received in the cavity 4616 of thetibial tray 4602 and, in some embodiments, the tab 4640 of the rim 4632of the tibial insert 4604 is received in the slot 4622 defined in theside surface 4614 of the tibial tray 4602. As discussed above, the metalring 4630 secured to the stem 4628 of the tibial insert 4604 is incontact with the inner sidewall 4620 of the tibial tray 4602 to form afriction lock therebetween. Additionally, the rim 4632 of the tibialinsert 4604 is in contact with the sidewall 4614 of the platform 4606 toform another friction lock therebetween. The friction locks and the tab4640 and slot 4622 (in some embodiments) cooperate to restrict orprevent rotation of the tibial insert 4604 relative to the tibial tray4602, to reduce micro-motion between the tibial insert 4604 and thetibial tray 4602, and/or to prevent lift-off of the tibial insert 4604relative to the tibial tray 4602.

A rotating tibial insert, similar to the tibial insert 794, may be usedwith the tibial tray 4602 in place of the non-rotating tibial insert4604. The rotating tibial insert may be coupled to the tibial tray 4602in a manner similar to the non-rotating tibial insert 4604. To do so,the rotating tibial insert is positioned such that a stem of therotating tibial insert is received in the cavity 4616 of the tibial tray4602. Because the rotating tibial insert create a friction lock with thetibial tray 4602, the rotating tibial insert is free to rotate about anaxis defined by the stem of the rotating tibial insert.

Referring now to FIG. 107, in another embodiment, a prosthetic kneesystem 4700 includes a tibial tray 4702 and a fixed or non-rotatingtibial insert 4704. The tibial insert 4704 is illustratively formed froma polymer material, but may be formed from other materials, such as aceramic material, a metallic material, a bio-engineered material, or thelike, in other embodiments. Similarly, the tibial tray 4702 isillustratively formed from a metallic material, but may be formed fromother materials, such as a ceramic material, a polymer material, abio-engineered material, or the like, in other embodiments.

The tibial tray 4702 includes a platform 4706 and a stem 4708. Theplatform 4706 includes an upper surface 4710 and a bottom surface 4712.The stem 4708 extends downwardly from the bottom surface 4712 of theplatform 4706. The platform 4706 includes a rim 4714 extending upwardlyfrom the upper surface 4710. The rim 4714 has an inwardly sloping taper.Illustratively, the rim 4714 is defined along the periphery of the uppersurface 4710 and defines an inner recessed area 4716. The illustrativerim 4714 also defines a closed path. However, in other embodiments, therim 4714 may be embodied as a number rim sections and/or otherwise notextend the entirety of the periphery of the upper surface 4710.

Again, as discussed with previous embodiments, the tibial tray 4702 isconfigured to be coupled to a surgically-prepared surface of theproximal end of a patient's tibia (not shown). When the tibial tray 4702is so coupled, the stem 4708 is embedded in patient's tibia to therebysecure the tibial tray 4702 to the patient's bone. In some embodiments,a stem extension (not shown) may include coupled to the stem 4708 toincrease the overall length of the stem 4708 and improve the stabilityof the tibial tray 4702 relative to the patient's bony anatomy.

The non-rotating tibial insert 4704 includes an upper bearing surface4720, a bottom surface 4722, and a side surface 4724 extending betweenthe upper bearing surface 4720 and the bottom surface 4722. The upperbearing surface 4720 is configured to contact a pair of natural orprosthetic femoral condyles of the patient. The tibial insert 4704 alsoincludes a metal ring 4730 secured to the side surface 4724. The metalring 4730 is configured and positioned such that an outer surface 4732of the metal ring 4730 is planar with the side surface 4724 of thetibial insert 4704 and a bottom surface 4734 of the metal ring 4730 isplanar with the bottom surface 4734 of the tibial insert 4704. The metalring 4730 has an inwardly sloping taper that corresponds to the taper ofthe rim 4714 of the tibial tray 4702. The tapers of the metal ring 4730and the rim 4714 are designed such that when the non-rotating tibialinsert 4704 is coupled to the tibial tray 4702, the metal ring 4730 andthe rim 4714 contact each other and form a friction lock therebetween.In one particular embodiment, the tapers of the metal ring 4730 and therim 4714 are embodied as corresponding Morse tapers. For example, in oneparticular embodiment, a Morse taper having a taper-per-foot in therange of about 0.59858 to about 0.63151 may be used. However, in otherembodiments, other types of friction lock tapers may be used.

The tibial insert 4704 is configured to be coupled to the tibial tray4702 in use. To do so, the tibial insert 4704 is positioned such that aportion thereof is received in the inner recessed area 4716 of thetibial tray 4702. When so positioned, the bottom surface 4722 of thetibial insert 4704 is in contact with the upper surface 4710 of theplatform 4706 of the tibial tray 4702. In addition, the rim 4714 of thetibial tray 4702 contacts the metal ring 4730 of the tibial insert 4704and forms a friction lock therebetween. The friction lock restricts orprevents rotation of the tibial insert 4704 relative to the tibial tray4702, reduces micro-motion between the tibial insert 4704 and the tibialtray 4702, and/or prevents lift-off of the tibial insert 4704 relativeto the tibial tray 4702.

Referring now to FIG. 108, in another embodiment, a prosthetic kneesystem 4800 includes a tibial tray 4802 and an adjustable stem 4804. Thetibial tray 4802 and adjustable stem 4804 are illustratively formed froman implantable metallic material, but may be formed from othermaterials, such as a ceramic material, a polymer material, abio-engineered material, or the like, in other embodiments.

The tibial tray 4802 includes a platform 4806 having an upper surface4808 and a bottom surface 4810. The tibial tray 4802 also includes aguide track 4812 that extends downwardly from the bottom surface 4810 ofthe tibial tray 4802. Illustratively, the guide track 4812 extendsacross the bottom surface of the platform 4806 in the medial/lateraldirection, but may extend in other directions in other embodiments. Theguide track 4812 includes an anterior sidewall 4814 and a posteriorsidewall 4816. Each of the sidewalls 4814, 4816 include a respective lip4818 extending inwardly therefrom to define an opening 4820therebetween.

The stem 4804 includes an elongated shaft 4822 and a mounting end 4824defined on a proximal end of the elongated shaft 4822. The mounting end4824 includes a neck 4826 and a flange 4828 defined at an end of theneck 4826. The flange 4828 is sized to be received in the opening 4820of the guide track 4812. That is, the stem 4804 may be coupled to thetibial tray 4802 by positioning the stem 4804 such that the flange 4828of the mounting end 4824 is received in the guide track 4812 and theneck 4826 of the mounting end 4824 is positioned in the opening 4820defined between the lips 4818. The stem 4804 may then be slid orotherwise positioned to the desired location along the guide track 4812.Once positioned in the desired location, the stem 4804 may be secured tothe tibial tray 4802 via use of a fastener or via compression of theflange 4828 against the elongated shaft 4822 of the stem 4804. That is,the distance between the flange 4828 and the base of the neck 4826 maybe adjustable by, for example, screwing or threading the mounting end4824 into a threaded aperture (not shown) defined in the end of theelongated shaft 4822.

Referring now to FIGS. 109-111, in another embodiment, a prosthetic kneesystem 4900 includes a tibial tray 4902 and an adjustable stem 4904. Thetibial tray 4902 and adjustable stem 4904 are illustratively formed froman implantable metallic material, but may be formed from othermaterials, such as a ceramic material, a polymer material, abio-engineered material, or the like, in other embodiments.

The tibial tray 4902 includes a platform 4906 having an upper surface4908 and a bottom surface 4910. The tibial tray 4902 also includes arecessed elongated opening 4912 in the upper surface 4908 and a recessedguide track 4914 in the bottom surface 4910. The guide track 4914 isdefined in the bottom surface 4910 in a medial/lateral direction, butmay be defined in other directions in other embodiments. Additionally,although the illustrative tibial tray 4902 includes a single guide track4914, the tibial tray 4902 may include additional guide tracks in otherembodiments. For example, as illustrated in FIG. 111, the tibial tray4902 may include a guide track 4916 that is defined in the bottomsurface 4910 in an anterior/posterior direction such that the positionof the stem 4904 relative to the tibial tray 4902 may be configured ineither a medial/lateral direction or an anterior/posterior direction

The illustrative guide track 4914 is substantially dovetailed and isconfigured to receive a portion of the stem 4902. The guide track 4914includes an anterior sidewall 4920 and a posterior sidewall 4922. Thesidewalls 4920, 4922 are inwardly sloped to define an opening 4924 inthe bottom surface 4910 therebetween. However, in other embodiments, theguide track 4914 may have other shapes such as a substantiallyrectangular shape. The illustrative guide track 4914 is an open trackhaving open ends. However, in other embodiments, the guide track 4914may be a closed track having one or both ends closed.

The stem 4904 includes an elongated shaft 4930 and a mounting end 4932defined on a proximal end of the elongated shaft 4930. The mounting end4932 has a shape corresponding to the shape of the guide track 4914 suchthat the mounting end 4932 may be received therein. In the illustrativeembodiments of FIGS. 109 and 110, the mounting end 4932 has asubstantially dovetail shape, but may have other shapes corresponding tothe shape of the guide track 4914 in other embodiments. The mounting end4932 is sized to be received in the guide track 4914. Once so received,the stem 4904 may then be slid or otherwise positioned to the desiredlocation along the guide track 4914. Once positioned in the desiredlocation, the stem 4904 may be secured to the tibial tray 4902 via useof a fastener 4934, which may be inserted through the elongated opening4912 defined in the upper surface 4908 of the tibial tray 4902. Becausethe elongated opening 4912 is recessed in the upper surface 4908, thehead of the fastener 4934 is positioned at or below the upper surface4908.

Referring now to FIGS. 112-117, in other embodiments, the tibial tray4902 may include a number of recessed elongated openings 4950 in placeof the guide track 4914. As illustrated in FIG. 112, the openings 4950are defined in the upper surface 4908 of the platform 4906.Illustratively, each opening 4950 is curved, which allows for stemplacement in both the anterior/posterior and medial/lateral directions.Although the illustrative tibial tray 4902 includes five recessedelongated openings 4950, it should be appreciated that in otherembodiments, any number of elongated openings 4950 may be used.Additionally, the direction, curvature, and overall configuration ofeach recessed elongated opening 4950 may be modified based on theparticular application and/or implementation.

As shown in FIG. 114, the number of elongated openings 4950 allow a stem4970 to be positioned in any one of a number of locations. The stem 4970includes a threaded aperture 4952 defined in a mounting end 4954. Thestem 4970 may be secured to the tibial tray 4902 by positioning afastener 4956 in the elongated opening 4950 and threading the fastener4956 into the threaded aperture 4952 as illustrated in FIG. 114. Asdiscussed above, the elongated openings 4950 are recessed such that thehead of the fastener 4956 is at or below the upper surface 4908 when thestem 4970 is secured to the tibial tray 4902. As shown in FIG. 115, eachopening 4950 may be defined by inwardly sidewalls 4960. As illustratedin FIG. 116, the stem 4970 may be secured to the tibial tray 4902 at adesired angle relative to the tibial tray 4902 via use of a shim 4962.The angle of attachment may be selected based on the thickness of theshim 4962. In other embodiments, the sidewalls 4960 defining the opening4950 are curved such that a fastener 4964 having a curved head may beused to secure the stem 4970 to the tibial tray 4902 in an angledposition as illustrated in FIG. 117. In such embodiments, the mountingend 4954 of the stem 4970 may have a corresponding slope.

In some embodiments, the tibial tray 4902 may include an upwardlyextending sidewall 4980 about the periphery of the upper surface 4908 asillustrated in FIG. 113. In such embodiments, the tibial tray 4902 mayinclude a number of cross-members 4982 secured to the sidewall 4980. Thenumber of cross-members 4982 may extend across the upper surface 4908 ofthe tibial tray 4902 to provide an increased rigidity to the tibial tray4902. It should also be appreciated that the sidewall 4980 may extenddownwardly from the bottom surface 4910 of the tibial tray 4902 in otherembodiments.

Referring now to FIGS. 118-120, in another embodiment, a prosthetic kneesystem 5000 includes a tibial tray 5002 and an adjustable stem 5004. Thetibial tray 5002 and adjustable stem 5004 are illustratively formed froman implantable metallic material, but may be formed from othermaterials, such as a ceramic material, a polymer material, abio-engineered material, or the like, in other embodiments.

The tibial tray 5002 includes a platform 5006 having an upper surface5008 and a bottom surface 5010. The tibial tray 5002 includes a pair ofguide rails 5012 extending downwardly from the bottom surface 5010.Additionally, the tibial tray 5002 includes an elongated opening 5014defined in the upper surface 5008 between the guide rails 5012.Illustratively, the guide rails 5012 extend across the bottom surface5008 of the platform 5006 in the medial/lateral direction, but mayextend in other directions in other embodiments. The guide rails 5012have a substantially rectangular shape, but may have other shapes inother embodiments.

The stem 5004 includes an elongated shaft 5020 and a mounting end 5022defined on a proximal end of the elongated shaft 5020. The mounting end5022 includes a number of grooves 5024 defined therein. The grooves 5024are configured to receive the guide rails 5012 of the tibial tray 5002.That is, the grooves 5024 have a shape and a separation distancecorresponding to the guide rails 5012. Illustratively, as shown in FIGS.119 and 120, the stem 5004 includes two pairs of grooves 5024 such thatthe stem 5004 may be coupled to the tibial tray 5002 in a number oforientations. To do so, the stem 5004 is positioned such that the rails5012 are received in the desired pair of grooves 5024. The stem 5004 maythen be slid or otherwise positioned to the desired location along theguide rails 5012. Once positioned in the desired location, the stem 5004may be secured to the tibial tray 5002 via use of a fastener 5026, whichmay be inserted through the elongated opening 5014 defined in the uppersurface 5008 of the tibial tray 5002. Because the elongated opening 5014is recessed in the upper surface 5008, the head of the fastener 5026 ispositioned at or below the upper surface 5008.

Referring now to FIGS. 121 and 122, in another embodiment, a prostheticknee system 5100 includes a femoral component 5102, an stem 5104, and anadaptor 5122 coupled to the femoral component 5102 and the stem 5104.The femoral component 5102, the stem 5104, and the adaptor 5122 areillustratively formed from an implantable metallic material, but may beformed from other materials, such as a ceramic material, a polymermaterial, a bio-engineered material, or the like, in other embodiments.

The femoral component 5102 is configured to be coupled to asurgically-prepared surface of the distal end of a patient's femur (notshown). When the femoral component 5102 is coupled to the patient'sfemur and the stem 5104 and the adaptor 5122 are coupled to the femoralcomponent 5102 as discussed below, the stem 5104 is embedded in thepatient's bone. The femoral component 5102 may be secured to thepatient's femur via use of bone adhesive or other attachment means. Thefemoral component 5102 includes a pair of condyles 5106. In use, thecondyles 5106 replace the natural condyles of the patient's femur andare configured to articulate on the proximal end of the patient'snatural or surgically-prepared tibia.

The femoral component 5102 includes a platform 5108 defined between thecondyles 5106. The platform 5108 includes a guide track 5110 definedtherein. The illustrative guide track 5110 is substantially dovetailedand is configured to receive a portion of the adaptor 5122. The guidetrack 5110 includes an anterior sidewall 5112 and a posterior sidewall5114. The sidewalls 5112, 5114 are inwardly sloped to define an opening5116 in the platform 5108 therebetween. However, in other embodiments,the guide track 5110 may have other shapes such as a substantiallyrectangular shape. The illustrative guide track 5110 is an open trackhaving open ends. However, in other embodiments, the guide track 5110may be a closed track having one or both ends closed.

The adaptor 5122 includes a mounting end 5130 configured to be receivedin the guide track 5110. That is, the mounting end 5130 has a shapecorresponding to the shape of the guide track 5110 such that themounting end 5130 may be received therein. In the illustrativeembodiments of FIGS. 121 and 122, the mounting end 5130 has asubstantially dovetail shape, but may have other shapes corresponding tothe shape of the guide track 5110 in other embodiments. The mounting end5130 of the adaptor 5122 is sized to be received in the guide track5110. Once so received, the adaptor 5122 (and the stem 5104) may be slidor otherwise positioned to the desired location along the guide track5110. Once positioned in the desired location, the adaptor 5122 may besecured to the femoral component 5102 via use of a fastener 5124, whichmay be inserted through the opening 5116 defined in the platform 5108 ofthe femoral component 5102.

In some embodiments, the adaptor 5122 is integral with the stem 5104.However, in other embodiments, the adaptor 5122 is separate from thestem 5104. In such embodiments, the adaptor 5122 includes a mounting end5132 that is configured to be coupled to the stem 5104. For example, insome embodiments, the mounting end 5132 may include a threaded aperture(not shown) configured to receive a threaded stud (not shown) defined onthe end of the stem 5104. Alternatively, the mounting end 5132 mayinclude a threaded stud configured to be received in a threaded aperturedefined in the end of the stem 5104. Regardless, in such embodiments,the stem 5104 is removably coupleable to the adaptor 5122 via themounting end 5132. It should be appreciated that in such embodiments,the adaptor 5122 may also be used with other orthopaedic prostheses. Forexample, the adaptor 5122 may be used with the tibial tray 4902illustrated in and described above in regard to FIG. 110. That is, themounting end 5130 of the adaptor 5122 may be positioned in the guidetrack 4914 and secured to the tibial tray 4902 via the fastener 4934 orother securing device. The stem 5104 or other stem may then be securedto the mounting end 5132 of the adaptor as discussed above. In this way,the adaptor 5122 may be selectively used with a tibial tray or a tibialinsert to facilitate the coupling of a stem thereto.

While many prosthetic knee systems and assemblies described aboveinclude a single tibial tray, non-rotating or fixed tibial insert, androtating tibial insert, it is within the scope of this disclosure toinclude other prosthetic knee systems having one or more tibial trays,one or more tibial inserts, and/or one or more locking mechanisms orother components associated with the aforementioned tray(s) andinsert(s). A first combination of the components of such a prostheticknee system provides a rotating tibial assembly whereby the tibialinsert is able to rotate about an axis relative to the tibial tray. Asecond combination of the components such a prosthetic knee systemprovides a non-rotating or fixed knee assembly whereby the tibial insertis fixed relative to the tibial tray and is not able to rotate about theaxis. As such, it is within the scope of this disclosure to includeother prosthetic knee systems including components which may be arrangedto provide for both a rotating knee assembly and a non-rotating kneeassembly.

Many different features are disclosed within FIGS. 1-122 herein in orderto couple various tibial trays and tibial inserts together in order toprevent rotation of the tibial insert relative to the tibial tray, toreduce or minimize micro-motion between the tibial insert and the tibialtray, and/or to prevent lift-off of the tibial insert relative to thetibial tray, for example. These features may be located on or withineach tibial insert and/or tibial tray. Alternatively, these features maybe embodied by components separate from the tibial insert and tibialtrays disclosed herein. Regardless, it is within the scope of thisdisclosure for any one or more of these features to be used incombination with each other and/or in combination with any of theembodiments disclosed herein.

While the concepts of the present disclosure have been illustrated anddescribed in detail in the drawings and foregoing description, such anillustration and description is to be considered as exemplary and notrestrictive in character, it being understood that only the illustrativeembodiments have been shown and described and that all changes andmodifications that come within the spirit of the disclosure are desiredto be protected.

There are a plurality of advantages of the present disclosure arisingfrom the various features of the apparatus and methods described herein.It will be noted that alternative embodiments of the apparatus andmethods of the present disclosure may not include all of the featuresdescribed yet still benefit from at least some of the advantages of suchfeatures. Those of ordinary skill in the art may readily devise theirown implementations of an apparatus and method that incorporate one ormore of the features of the present disclosure and fall within thespirit and scope of the present disclosure.

1. An orthopaedic prosthesis comprising: a tibial tray configured to becoupled to a surgically-prepared surface of the proximal end of a tibia,the tibial tray including (i) a platform having an upper surface and abottom surface and (ii) a cavity defined by an inner sidewall and havingan opening defined in the upper surface of the platform; a tibial insertcoupled to the tibial tray, the tibial insert having (i) an upperbearing surface configured to contact a pair of femoral condyles, (ii) abottom surface in contact with the upper surface of the tibial tray, and(iii) a stem extending downwardly from the bottom surface and receivedin the cavity of the tibial tray, the stem including a distal end havinga threaded internal passageway; a screw positionable in the threadedinternal passageway of the stem, wherein: (i) the distal end of the stemhas a first width when the screw is positioned in the threaded internalpassageway and (ii) the distal end of the stem has a second width whenthe screw is removed from the threaded internal passageway, the firstwidth being greater than the second width; and wherein the tibial insertis rotatable with respect to the tibial tray when the screw is removedfrom the threaded internal passageway and prevented from rotating withrespect to the tibial tray when the screw is positioned in the threadedinternal passageway.
 2. The orthopaedic prosthesis of claim 1, whereinthe distal end of the stem includes a vertical slit, the vertical slitsized to allow the width of the distal end of the stem to be increased.3. The orthopaedic prosthesis of claim 1, wherein the stem includes anouter wall, the outer wall being forced against the inner sidewall ofthe tibial tray when the screw is positioned in the first position. 4.The orthopaedic prosthesis of claim 1, wherein the inner sidewall of thetibial tray includes a slot defined therein and the distal end of thestem includes an outer rim, the outer rim being received in the slot ofthe inner sidewall.
 5. The orthopaedic prosthesis of claim 1, whereinthe tibial insert includes a tapered bore defined therethrough, thetapered bore extending from the upper bearing surface to the bottomsurface, the threaded internal passageway forming a portion of thetapered bore.